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Maeda LC785M-8B Operation Manual Download Page 1

557E-OM1202-00 

OPERATION MANUAL

 

 
 
 
 
 
 
 
 

CRAWLER CRANE 

 

 

 

Serial No. 32024 and up

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 

 

 

Unsafe use of this machine may cause serious injury or death. Operators 
must read this manual before operating this machine. This manual should 
be kept near the machine for reference and periodically reviewed by all 
personnel who will come into contact with it. 

 

NOTICE 

MAEDA has Operation Manuals written in some other languages. If a 
foreign language manual is necessary, contact your local distributor for 
availability. 

Summary of Contents for LC785M-8B

Page 1: ...ust read this manual before operating this machine This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it NOTICE MAEDAhas Operation Manuals written in some other languages If a foreign language manual is necessary contact your local distributor for availability ...

Page 2: ......

Page 3: ...2 PREPARATIONS OF SAFETY OPERATION 2 3 1 3 PRECAUTIONS FOR FIRE PREVENTION 2 5 1 4 PRECAUTIONS WHEN GETTING ON OR OFF 2 6 1 5 OTHER PRECAUTIONS 2 7 2 DRIVING RELATED PRECAUTIONS 2 8 2 1 PRECAUTIONS FOR JOB SITE 2 8 2 2 PRECAUTIONS WHEN STARTING ENGINE 2 11 2 3 PRECAUTIONS WHEN STARTING TO MOVE MACHINE 2 13 2 4 PRECAUTIONS WHEN WORKING WITH CRANE 2 16 3 TRANSPORT PRECAUTIONS 2 24 4 TOWING PRECAUTIO...

Page 4: ...71 2 4 7 MOMENT LIMITER WORKING ENVELOPE SETTING 3 71 2 4 8 PICK CARRY STAITIONARY MODE SELECT 3 72 2 4 9 MOMENT LIMITER ERROR CAUSES AND ACTIONS TO TAKEN 3 73 2 5 OVER HOIST DETECTOR 3 74 2 6 AIR CONDITIONER CONTROLS 3 75 2 6 1 AIR CONDITIONER CONTROL PANEL 3 75 2 6 2 AIR CONDITIONER OPERATION METHOD 3 79 2 6 3 USE AIR CONDITIONER WITH CARE 3 85 2 6 4 INSPECTION AND MAINTENANCE OF AIR CONDITIONER...

Page 5: ...E TRAVELLING POSTURE 3 144 3 7 STARTING MOVING STOPPING MACHINE 3 145 3 8 STEERING MACHINE 3 149 3 9 SLEWING 3 151 3 10 WORKING MODE OPERATION 3 152 3 11 CAUTIONS BEFORE CRANE OPERATION 3 153 3 12 OPERATIONS BEFORE OPERATING THE CRANE 3 155 3 13 CRANE OPERATION POSTURE 3 157 3 14 HOOK RAISING LOWERING OPERATION 3 158 3 14 1 NORMAL HOOK RAISING LOWERING OPERATION 3 158 3 14 2 HIGH SPEED HOOK RAISIN...

Page 6: ...LOADING UNLOADING 3 191 5 1 1 LOADING 3 192 5 1 2 SECURING MACHINE 3 194 5 1 3 UNLOADING 3 195 5 2 LIFTING MACHINE 3 196 5 2 1 LIFTING THE MACHINE IN THE BOOM LOWERED POSTURE 3 196 5 2 2 LIFTING UP THE MACHINE IN THE BOOM RAISED POSTURE 3 198 5 3 TRANSPORTATION PROCEDURE 3 199 6 HANDLING IN COLD WEATHER 3 200 6 1 PREPARING FOR LOW TEMPERATURE 3 200 7 LONG TERM STORAGE 3 202 7 1 BEFORE STORAGE MACH...

Page 7: ...CHINE 4 17 10 2 CHECKING BEFORE OPERATION 4 17 10 3 IRREGULAR MAINTENANCE 4 18 10 4 MAINTENANCE EVERY 50 HOURS 4 42 10 5 MAINTENANCE EVERY 100 HOURS 4 44 10 6 MAINTENANCE EVERY 250 HOURS 4 46 10 7 MAINTENANCE EVERY 500 HOURS 4 51 10 8 MAINTENANCE EVERY 1000 HOURS 4 60 10 9 MAINTENANCE EVERY 2000 HOURS 4 71 10 10 MAINTENANCE EVERY 4000 HOURS 4 72 10 11 MAINTENANCE EVERY 5000 HOURS 4 73 11 BLEEDING ...

Page 8: ...ER DISPLAY 6 20 7 2 PRIOR TO USE MOMENT LIMITER SAFETY PRECAUTIONS 6 22 7 3 MOMENT LIMITER FUNCTIONS 6 23 7 3 1 FLY JIB MODE SWITCH DISPLAY 6 23 7 4 SETTING OF OPERATING CONDITIONS 6 24 7 4 1 FLY JIB MODE SWITCH FLY JIB OPERATION 6 24 8 OPERATIONS 6 25 9 TRANSPORTATIONS 6 25 10 INSPECTION AND MAINTENANCE 6 26 10 1 MAINTENANCE EVERY 50 HOURS 6 26 11 SPECIFICATIONS 6 27 11 1 SPECIFICATIONS 6 27 11 2...

Page 9: ...INTRODUCTION 1 INTRODUCTION 1 2 2 FOR SAFE USE OF MACHINE 1 3 3 MACHINE OVERVIEW 1 4 4 QUALIFICATION FOR OPERATION 1 6 5 TERMINOLOGY 1 7 6 NECESSARY INFORMATION FOR SERVICE 1 12 1 1 ...

Page 10: ...to carry out periodic reference to the manual Only those who have a thorough understanding of the fundamental procedures provided in this manual are allowed to operate this machine Keep this manual handy for reference when necessary Should you lose or damage this manual contact Maeda or our sales service agency immediately for ordering a new manual This manual should always accompany this machine ...

Page 11: ...st be observed for the sake of the machine and what will be of help CAUTION This denotes that failure to handle the machine properly may damage the machine or shorten its life 1 3 This denotes helpful information NOTES Not only procedures for operation inspection and maintenance of this machine described in this manual but also safety precautions that may pertain to the case where this machine is ...

Page 12: ...ithin the rated total load for normal crane operation or pick and carry operation 3 2 MACHINE CONFIGURATION EXTERNAL VIEW 1 Undercarriage In this manual the terms front rear left and right refer to the travel direction as viewed from the operator s seat when the operator s seat is facing the front and the sprocket a is at the rear of the machine 2 Upper structure 3 Safety device Boom slewing motio...

Page 13: ...hydraulic automatic locking device derricking cylinder hydraulic automatic locking device alarm buzzer machine tip over alarm device level working status lamp crane lock lever 3 3 MACHINE FUNCTIONS 1 UNDERCARRIAGE The carrier is equipped with crawlers which enables this machine to enter into rough or soft terrain 2 travel lever operation enables not only direction changes forward backward and righ...

Page 14: ...ned in this manual shall be observed for safety assurance during operation of the machine 4 1 QUALIFICATION FOR CRANE OPERATION Only personnel that have obtained the required license or training stipulated by laws and regulations applicable to the place of use are qualified to operate this machine Contact the relevant government office or our sales service agency for further information 1 6 ...

Page 15: ...hoisting accessories hooks and sling etc from the rated total load which is a maximum load for hoisting 3 WORKING RADIUS This is a horizontal distance between the axis of slewing and the hook centre 4 BOOM LENGTH This is a distance between the boom primary pin and the sheave pin of the end boom 5 BOOM ANGLE This is an angle which the boom forms from horizontal 6 LIFTING HEIGHT ABOVE GROUND This is...

Page 16: ...round in the figure at right The same working radius is applied to points A and B 2 The diagram of working radius and lifting height shows the relationships of the working radius boom angle and lifting height at no load allowing for no deflection in the boom A deflection occurs in the boom when an object is hoisted which causes the working radius to increase slightly The rated total load decreases...

Page 17: ...d is a load including the mass of a hoisting accessory hook 90kg LC785M 8 Rated Total Load Chart 4 63m boom 7 38m boom 10 13m boom 12 88m boom 15 63m boom Working radius m Stationary Pick Carry Stationary Pick Carry Stationary Pick Carry Stationary Stationary 2 00 4900 2000 4900 2000 2600 1400 2000 2 10 4900 2000 4630 2000 2600 1400 2000 2 50 3800 2000 3760 2000 2600 1400 2000 1400 2 70 3310 1950 ...

Page 18: ...m Boom 4 12 88m Boom and 5 15 63m Boom in the preceding boxes in the rated total load chart 1 1 4 63m Boom All the booms are retracted 2 2 7 38m Boom With booms 3 4 and 5 retracted boom 2 is fully extended Boom 2 is to apply to crane operation with boom 2 extended even if only slightly 3 3 10 13m Boom With boom 2 fully extended booms 3 4 and 5 are extended 1 3 half of the mark 1 passes boom 2 Boom...

Page 19: ...ended 2 3 half of the mark 2 passes boom 2 Boom 4 is to apply to crane operation with half of the mark 1 on boom 3 passes boom 2 5 5 15 63m Boom All the booms are fully extended Boom 5 is to apply to crane operation with half of the mark 2 on boom 3 passes boom 2 1 11 ...

Page 20: ...s service agency at the time of requesting repair service or ordering spare parts Machine serial number engraved on plate Located at the bottom of operator cab Information of EPA Engine serial number engraved on plate Located on the side of intake pipe EPA Environmental Protection Agency 1 12 ...

Page 21: ...Gauges and meters To be shown at service meter section on machine monitor 1 13 ...

Page 22: ...1 14 ...

Page 23: ... PRECAUTIONS 2 24 4 TOWING PRECAUTIONS 2 25 5 MAINTENANCE PRECAUTIONS 2 26 6 SAFETY LABEL LOCATIONS 2 33 All the safety precautions defined in this manual should always be read and observed Failure to follow the safety precautions can cause serious personal injury or death 2 1 ...

Page 24: ...ed to receive education and training in the handling methods and other subjects from the applicable office and obtain sufficient driving operation skills before work COMMIT TO SAFE OPERATION Obey the instructions and signs given by the manager and work supervisor and observe safety first during the work Obey the crane work basics during operation Before starting driving or work always carry out th...

Page 25: ...e lower the hoisted load to the ground stop the engine and remove the engine ignition key TEMPORARY STORAGE WHEN ABNORMALITY IS FOUND WITH MACHINE If the Machine is found to have an abnormality and is therefore placed in storage awaiting service apply the following measures to notify all persons in the office that its use is prohibited due to failure Attach warning tags on the operation lever and ...

Page 26: ...EP OPERATOR S COMPARTMENT CLEAN When entering operator s compartment always remove all mud and oil from the soles of your shoes Do not leave parts or tools lying around the operator s compartment ns and may cause fire Do not use cellular telephones inside operator s compartment when driving or operating the machine If you operate the pedal with mud or oil on to your shoes your foot may slip and th...

Page 27: ...horized persons to enter When carrying out grinding or welding work on the chassis move any flammable materials to a safe place before starting FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL Remove any dry leaves chips pieces of paper dust or any other flammable materials accumulated or affixed around the engine exhaust manifold muffler battery or inside the covers FIRE COMING FROM ELECTRIC WIR...

Page 28: ...p on or off the machine Never jump on or off a moving machine If the machine starts to move when there is no operator on the machine do not jump on to the machine and try to stop it PRECAUTIONS WHEN LEAVING OR STANDING UP FROM OPERATOR S SEAT Before standing up from operator s seat such as when adjusting the operator s seat always store the crane completely set lock lever 1 securely to the LOCK po...

Page 29: ...g us ATTACHMENT INSTALLATION When installing optional parts or attachments there may be problems with safety or legal restrictions Therefore contact our sales service agency for advice Any injuries accidents or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Maeda When installing and using optional attachments read the instruction manu...

Page 30: ...nkments or near excavated ditches there is a hazard that weight and vibration of the machine will cause the soil to collapse Before starting operations take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling ENSURE GOOD VISIBILITY This machine is equipped with mirrors to improve the visibility but even with mirrors there are places which cannot be seen ...

Page 31: ...d shoes and rubber gloves and be careful that the body parts unprotected by rubber or other insulation do not contact the wire rope or the Machine frame Place a guide and let him her watch so that the boom wire rope or Machine frame does not go to close to the electrical cable Before doing so decide on the emergency signs and other necessities Ask the electricity company for the voltage in the ele...

Page 32: ...k into service Attempting to do so may cause unexpected accidents and enhances failures Ask us or our sales service agency for repair CAUTIONS WHEN WORKING WITH THE CRANE IN A LOCATION WITH HIGH OUTPUT OF MICROWAVE EMISSION Working with the crane near a high output of microwave emission equipment such as radar or TV radio broadcast antenna may causes the crane construction to be exposed to the mic...

Page 33: ...ps See Operation 3 1 2 Checking Before Starting Engine Adjusting Operator s Seat for details Adjust the mirrors so that the rear of the machine and winch drum can be seen clearly from the operator s seat See Operation 3 1 2 Checking Before Starting Engine Adjusting Mirrors for details Check pedals for piled up mud or alien substances which may disturb their movement and remove to ensure correct fu...

Page 34: ... operate improperly upon its next use and cause unexpected accidents CAUTIONS WHEN STARTING UP USING BOOSTER CABLE The wrong booster cable connection method may result in fire so always observe the followings When starting up the engine using a booster cable is attempted always arrange 2 persons one in the cabin and another with the battery When starting using another Machine be careful to prevent...

Page 35: ...chine Travelling Posture for details Do not travel when the hook block is not contained Before travelling set the machine so that sprocket A is behind the operator s seat If sprocket A is in front of the operator s cab the machine will move in the opposite direction from the operation of the levers front and rear travel is reversed left and right steering is reversed Be extremely careful when oper...

Page 36: ...mely careful not to let the crane hit anything BE CAREFUL WHEN TRAVELLING OVER SLOPES ALWAYS observe the following to prevent serious injuries and fatal accidents when travelling over a slope for unavoidable reasons For travelling on a slope always keep the correct travelling posture with the hook block secured to the hook block stowage wire rope in the front of the upper structure When the hook b...

Page 37: ...s frozen or stuck to the ground or other surfaces is dangerous Do not touch the metal surface with any part of your body such as a finger or hand during cold weather Attempting to contact a metal surface of the Machine under harsh cold weather may cause the skin to stick to the metal surface Remove snow and or ice from the Machine that causes the safety nameplates to be hard to read Be especially ...

Page 38: ...TER The moment limiter calculates the moments assuming the Machine is level If you work with the crane when the Machine is not level warnings and alarms are not issued even when the rated total load is near Always use the level to ensure that the machine is not at an angle Before using the moment limiter check that the boom angle display boom length display and real load display are displayed corr...

Page 39: ... The driver is requested to make sure no one is within the working radius of the crane before operating crane CAUTIONS UNDER COLD WEATHER Remove snow from and unfreeze the swing gear boom and winch related parts and check the movements before work Check the operation of winch brake Warm up the machine Attempting to operate the operation levers pedals and switches without enough warm up time causes...

Page 40: ...side of the boom may cause the Machine to tip or damage the boom Be very careful when working In a condition where wind blows to the front face of the boom the higher the boom is raised the more you may run a risk of overturning backward Be very careful when working in such conditions When an earthquake occurs abort working and wait until the earthquake is over The following table indicates approx...

Page 41: ... the loads may move and lose balance and cause tipping or some other cause of a serious accident Do not hoist more than one load even if the total is within the rated total load Hoisting of lengthy loads may cause the load to lose balance and is dangerous In case of lengthy loads hoist vertically by using a clamp or achieve balance of the hoisted load by applying a rope to both ends of the load CA...

Page 42: ...g an obstacle such as a tree or steelwork when hoisting a load If caught by an obstacle do not forcibly wind up the hoisted load but untangle the caught part before winding up Do not pull laterally pull toward you or hoist diagonally Doing so may cause the crane to tip or suffer damage Do not attempt to work with the crane when the view is bad due to location or weather it is dangerous Ensure brig...

Page 43: ...he hook block and load to fall causing serious accidents Be very careful to prevent over winding the hook block Be careful to prevent the wire rope and or hoisted load from contacting any obstacle such as a tree or steelwork when hoisting a load If caught by an obstacle do not forcibly wind up the load but untangle the caught part before winding up Do not use the winch drum wire rope in a random w...

Page 44: ...top gently Especially avoid sudden lever operations when the load is hoisted which may cause the load to swing and cause the Machine to lose balance and thus may damage the crane or tip the Machine Attempting to pull the load in or stand the load up by swinging operation is prohibited Do not attempt under any circumstance Be careful to prevent the wire rope and or hoisted load from contacting an o...

Page 45: ...or Pick and Carry Operation Always keep the correct posture as specified in the operation manual Refer to Operation 3 21 2 Posture for Pick and Carry Operation The hoisted load should be within a safe load range and kept in a height near the ground Arrange a person to guide the machine travelling Remove all the obstacles in the pick and carry path and keep out all persons Hoisting in the boom conf...

Page 46: ...from skidding over the ramps Remove any substances stuck to the ramps such as grease oil or ice and keep clean Be especially careful during rainy days where slips easily occur When loading or unloading the machine always keep it in a travelling posture and fix the hook block by the stowage wire rope See Operation 3 6 Machine Travel Posture for details When loading or unloading set the engine rotat...

Page 47: ... rope For details of towing see Operation 8 3 How to tow the machine Always wear leather gloves when handling wire rope During the towing operation never stand between the towing objects and the machine being towed Never tow a machine on a slope Never use a wire rope which has cut strands A reduced diameter C or kinks B There is danger that the rope may break during the towing operation 2 25 ...

Page 48: ... other tools lying around in the work place Wipe up all grease oil or other substances that will cause you to slip Always keep the work place clean and tidy to enable you to carry out operation safely If the work place is not kept clean and tidy there is the danger that you will trip slip or fall over and injure yourself When cleaning the ceiling window which is made of organic glass polycarbonate...

Page 49: ...ntenance with the engine running If maintenance must be carried out with the engine running carry out the operation with at least two workers and do as follows One worker must always sit in the operator s seat and be ready to stop the engine at any time All workers must maintain contact with the other workers When carrying out operations near the fan fan belt winch drum or other rotating parts the...

Page 50: ...ing concrete blocks to support the machine Concrete blocks easily crush even under small loads CLEAN BEFORE INSPECTION OR MAINTAIN Before starting an inspection or maintenance clean the Machine and prevent rubbish from entering the Machine and make sure that safety will be ensured during maintenance Attempting to inspect or maintain the machine whilst still dirty not only lessens the chance of loc...

Page 51: ...ye wash immediately with water and see the doctor as soon as possible If you have swallowed the battery fluid by mishap immediately drink huge quantity of water milk raw egg or vegetable oil and see the doctor as soon as possible Wipe with a wet clean cloth when cleaning the battery upper surface or related part Do not use organic solvent or detergent for instance gasoline or paint thinner Tighten...

Page 52: ...ircuit is still under pressure it will lead to serious injury so always do as follows Release the pressure in the hydraulic circuit Do not carry out any inspection or replacement work when the hydraulic system is under pressure Refer to Maintenance 12 Releasing the Internal Pressure from the Hydraulic System If there is any leakage from the piping or hoses the surrounding area will be wet so check...

Page 53: ...s service agency NOISE CAUTION When carrying out maintenance of the engine and you are exposed to noise for long periods of time wear ear covers or ear plugs while working If the noise from the machine is too loud it may cause temporary or permanent hearing problems SAFETY FIRST WHEN USING HIGH PRESSURE GREASE TO ADJUST TRACK TENSION Grease is pumped into the track tension adjustment system under ...

Page 54: ...efrigerant CAUTIONS WHEN TREATING WASTE Always observe the following to prevent environmental pollution of a district inhabited with humans or animals Do not dispose the waste oil down a water system such as sewage or river Observe the applicable legal regulations and rules when disposing harmful substance such as the machine oil fuel solvent filter or battery HOW TO CHOOSE A WIND WASHER LIQUID Us...

Page 55: ...ETY LABEL LOCATIONS Keep these labels clean all the time If lost apply again or replace with new one Labels other than the following safety labels exist Treat them the same SAFETY LABEL LOCATIONS IN CAB 2 33 ...

Page 56: ... SAFETY LABEL LOCATIONS ON CHASSIS 2 34 ...

Page 57: ... 1 Working range and rated total load chart 557 2221400 2 For your safe operation 556 3367900 2 2 35 ...

Page 58: ... 3 Moment limiter operation 557 2221500 4 Warning for operation inspection and maintenance 584 3469700 2 36 ...

Page 59: ...umber of parts reeving selector switch 553 3181800 1 6 Caution for emergency switch 7 Warning for blade operation 553 4266400 556 4575300 8 Never water wash inside cabin 9 Caution for wash 300 4213900 553 4266500 2 37 ...

Page 60: ... 10 Control pattern 556 3368100 11 Warning for Window 20U 98 21910 12 Front window Lock 22P 00 11170 13 Safety plate 09839 03000 2 38 ...

Page 61: ... 14 Warning tag 09963 03001 15 Portable Working range and rated total load chart 557 3488600 16 Warning for track tension adjusting 09657 A0881 2 39 ...

Page 62: ...eep off swing area 09133 A1681 18 Warning for winch 553 4267500 19 Lifting Position 09960 00801 4 places 20 Warning 553 4268000 2 places 21 Machine Weight 557 4632300 22 Do not Stand on here 584 4581700 2 40 ...

Page 63: ... for filling hydraulic oil 09653 A0481 24 Safety plate 09805 A0481 2 places 25 High temperature caution 349 4427800 26 Falling Hazard 557 4632500 27 Entanglement hazard 09667 A0481 28 Shock hazard 09808 A0881 2 41 ...

Page 64: ... 29 Safety plate 09659 A057B 2 42 30 Warning for hook block 553 4267400 2 places ...

Page 65: ...H SECTION 3 2 2 EXPLANATION OF DEVICES 3 6 3 MACHINE OPERATIONS AND CONTROLS 3 108 4 HANDLING WIRE ROPES 3 184 5 TRANSPORTATION 3 190 6 HANDLING IN COLD WEATHER 3 200 7 LONG TERM STORAGE 3 202 8 TROUBLES AND ACTIONS 3 203 3 1 ...

Page 66: ...NE EACH UNIT 8 Idler 1 Boom 9 Track 2 Working lamp 10 Blade cylinder 3 Boom derricking cylinder 11 Blade 4 Winch 12 Hook block 5 Head lamp 13 Over hoist detector 6 Sprocket and traveling motor 14 Working status lamp 7 Track frame 3 2 ...

Page 67: ... equipment control lever 18 Sun roof wiper switch 6 Travel pedals 19 Room lamp switch 7 Travel levers 20 Moment limiter transducer 8 Accelerator pedal 21 Emergency pump drive switch 9 Moment limiter display unit Not available for this machine 10 Moment limiter related switch box 22 Swing parking brake release switch 11 Machine monitor 23 Battery disconnect switch 12 Right work equipment control le...

Page 68: ...ant temperature monitor 19 Message monitor 5 Engine coolant temperature gauge 20 Air conditioner monitor 6 Hydraulic oil temperature gauge 21 Wiper monitor 7 Service meter Clock 22 Swing lock monitor 8 Hydraulic oil temperature monitor 23 Engine pre heating monitor 9 Working mode monitor 24 Auto decelerator monitor 10 Travel speed monitor 25 Charge level monitor 11 Fuel gauge 26 Function switch F1...

Page 69: ...1 2 2 MOMENT LIMITER RELATED SWITCH BOX 1 Moment limiter emergency stop cancel switch 2 Hook stowage switch 3 Winch speed selector switch 3 5 ...

Page 70: ...ONITOR AA Standard screen BB All lamps lit up screen CC Maintenance interval warning screen A Emergency monitors D Meter display portion pilot display B Caution monitors E Monitor switches portion C Basic check monitors NOTES One of the features of liquid crystal display panels is that there may be black spots spots that do not light up or white spots spots that stay lit up on the screen If there ...

Page 71: ...arting screen DD is displayed for 2 seconds the screen changes to the Standard screen AA NOTES When the engine is started the battery voltage may suddenly drop depending on the temperature and the battery condition If this happens the display on the machine monitor may momentarily go out but this does not indicate any abnormality STOPPING ENGINE WHEN SITUATION IS NORMAL When the starter switch is ...

Page 72: ... changes to the Maintenance interval warning screen CC or Error screen EE After displaying the Check before starting screen DD for 2 seconds the screen changes to the Maintenance interval warning screen CC After displaying the Maintenance interval warning screen CC for 30 seconds the screen changes to the Standard screen AA After displaying the Check before starting screen DD for 2 seconds the scr...

Page 73: ...re as follows Color when lit up Type of monitor When normal When abnormal At low temperature 1 Engine coolant temperature monitor Blue Red White 2 Hydraulic oil temperature monitor Blue Red White 3 Fuel level monitor Blue Red 4 Charge level monitor OFF Red 5 Engine oil pressure monitor OFF Red 6 Maintenance interval monitor OFF Red AA Standard screen BB All lamps lit up screen CC Maintenance inter...

Page 74: ...draulic oil temperature monitor ENGINE COOLANT TEMPERATURE MONITOR This monitor 1 warns operator that the engine coolant temp erature has risen If the engine coolant temperature becomes abnormally high the monitor shows abnormal display C The overheat prevention system is automatically actuated and the engine speed drops Stop operations and run the engine at low idling until monitor 1 change to no...

Page 75: ...isplay B Display A at low temperatures Monitor background D is white Display B at correct temperatures Monitor background D is blue Display C when condition is abnormal Monitor background D is red ENGINE OIL PRESSURE MONITOR This monitor 3 warns operator that the engine lubrication oil pressure has dropped If the engine lubrication oil pressure goes below normal level the monitor 3 lights up red S...

Page 76: ...nitor 3 Fuel level monitor 2 Hydraulic oil temperature monitor 4 Charge level monitor ENGINE COOLANT TEMPERATURE MONITOR If this monitor 1 shows low temperature display A carry out the warm up operation For details see Operation 3 3 1 Engine Warm Up This monitor 1 will show normal display B so carry out the warm up operation for engine This monitor 1 will show abnormal display C stop operations an...

Page 77: ...itor background D is red FUEL LEVEL MONITOR This monitor 3 lights up to warn that the operator that the level in the fuel tank is low When the remaining fuel level reaches approx 27 liters the monitor lights up red so add fuel as soon as possible CHARGE LEVEL MONITOR This monitor 4 warns the operator that there is an abnormality in the charging system when the engine is running If the battery is n...

Page 78: ...MAITENANCE INTERVAL MONITOR This monitor 1 lights up when the maintenance time gets close and remains lit after the maintenance time has already passed Lit yellow The maintenance interval is due within 30 hours Lit red The maintenance interval has already passed This monitor 1 Lights up when starter switch is turned to the ON position It goes off after 30 seconds and display changes to the Standar...

Page 79: ...e top of the screen consists of the pilot lamps to confirm the actuation of each function When the starter switch is turned to the ON position the pilot lamp lights up when the display items are functioning ENGINE PRE HEATING MONITOR This monitor 1 is displayed when preheating the engine before starting the engine in temperature below 0 C In cold weather when the starter switch is turned to the HE...

Page 80: ...or ON Auto deceleration actuated Monitor OFF Auto deceleration canceled For detail of positions of the auto deceleration switch see Operation 2 1 6 Monitor switches portion WORKING MODE MONITOR This monitor 5 displays the setting of the working mode The monitor display is as follows according to the operation of the working mode switch P mode For heavy load operations E mode For operations with em...

Page 81: ...e air conditioner Monitor lit up Air conditioner ON Monitor off Air conditioner OFF MESSAGE MONITOR The message monitor is not available for this machine This monitor 8 remains lit throughout operation IDLING STOP GUIDANCE If the levers are not operated for more than 5 minutes and the engine is idling the idling stop message is displayed on the monitor When waiting for work or stopping work for sh...

Page 82: ...Red range B position Engine speed changes to low idling engine coolant temperature monitor E shows abnormality display alarm buzzer sounds at same time The overheat prevention system continues to work until the indicator enters the green range When the engine is started if the indicator is at position C engine coolant temperature monitor E shows the low temperature display If this happens carry ou...

Page 83: ...is 20 C hydraulic oil temperature monitor E shows the low temperature display If this happens carry out the warm up operation For detail see Operation 3 3 2 Hydraulic Equipment Warm Up Display G at low temperatures Monitor background K is white Display H at correct temperatures Monitor background K is blue Display J when condition is abnormal Monitor background K is red FUEL GAUGE This gauge 12 sh...

Page 84: ...ay 12 hour or 24 hour displays are available To set or correct the time press function switch F6 user mode switch ECO GAUGE This gauge 14 shows the working load status When the gauge is in green range A the work load is light to medium When the gauge is in orange range B the load is heavy NOTES When the gauge enters the orange range B there is no abnormality on the machine but to protect the envir...

Page 85: ...uel consumption L mode For fine control operations B mode Not available for this machine ATT mode Not available for this machine NOTES B mode Breaker operation and ATT mode Crusher operation of this work mode selector switch are not availble for this machine When the monitor first appears it is automatically set to the mode in use when it was started the previous time Press switch 1 to display the...

Page 86: ...ly set as the working mode and the screen changes to Steps 3 and Steps 4 To return to the standard screen without changing the working mode press function switch F5 3 After selecting the desired mode press function switch F6 and the mode is displayed in the center of the monitor display Example If power mode is selected P 4 After 2 seconds the pilot monitor display at the top right of the screen i...

Page 87: ...he N position the engine speed drop after 4 seconds from the operating speed to idling speed This makes it possible to reduce fuel consumption If any lever is operated when the machine is in this condition engine speed will return to the previous operating speed to make it possible to perform operation 1 When auto deceleration switch 2 is pressed and the auto deceleration function is returned ON t...

Page 88: ...avel power is needed such as when traveling on soft ground or on slopes the speed automatically switches to low speed Lo so there is no need to operate the switch The monitor display stays at Hi NOTES Each time travel speed selector switch 3 is switched the mode is displyed on the monitor display and after 2 seconds the screen returns to the standard screen With engine rotation speed less than 160...

Page 89: ...usly pressed window washer fluid is sprayed out on the front glass When the switch is released the spray stops If switch 5 is kept pressed when the wiper is stopped the window washer fluid will spray and at the same time the wiper will be actuated continuously When switch 5 is released the wiper will continue to operate for 2 cycles and then stop If the wiper is moving intermittently and switch 5 ...

Page 90: ...he functions are displayed as follows Switch F3 Camera screen selector switch Switch F4 Service meter time display selector switch Switch F5 Maintenance mode switch Switch F6 User mode switch Switch F1 and F2 are auxiliary switches for expanded functions NOTES For explanation of each switch see Operation 2 1 7 Handling Function Switches AIR CONDITIONER SWITCH The air conditioner switches 8 consist...

Page 91: ... the content of each screen The function of switches A on each screen can be confirmed by guidance icons B displayed on top of each switch f there is no display in guidance icon B even if switch A is pressed it will not function Even if guidance icon B is pressed it will not function Press switch A immediately below the guidance icon display to operate the function 3 27 ...

Page 92: ...e standard screen it is possible to press the function switch F4 to switch the service meter and clock display at the top of the monitor display When the time is being displayed press the function switch F4 to switch to the service meter display 3 28 ...

Page 93: ... Default maintenance interval settings h a Maintenance items Maintenance items Default maintenance interval settings h Engine oil change 500 Engine oil filter change 500 Fuel main filter change 1000 Fuel pre filter change 500 Hydraulic oil filter change 1000 Hydraulic tank breather change 500 Damper case service Not available for this machine 1000 Final drive case oil change 1000 Swing machinery c...

Page 94: ...ept pressed the screen changes to the screen for resetting the remaining time for the selected item item highlighted in yellow NOTES When resetting the remaining time keep switch F6 pressed for at least 1 5 seconds If switch F6 isnot kept pressed for at least 1 5 seconds the switch operating sound can be heaard but the screen does not switch to the screen for resetting the remaining time If no swi...

Page 95: ... F5 The screen returns to the maintenance list screen On the reset screen if no switch is operated for more than 30 seconds the screen automatically switches to the maintenance list screen 2 The reconfirmation screen shown on the right is displayed 3 If switch F6 is pressed again The remaining time is reset and the screen switches to the maintenance list screen NOTES If it is desired to cancel the...

Page 96: ...h F4 Moves to previous item 1 line up When on the first line it moves to the last line on the previous page Switch F5 Returns to standard screen Switch F6 Switches to setting screen for selected item NOTES If no switch is operated for 30 seconds on the user menu screen the screen automatically returns to the previous screen The following item can be set a Not available for this machine b Not avail...

Page 97: ... be adjusted a or b from the selection menu screen for screen adjustment then press switch F6 The screen switches to the setting screen for the selected item On the mode selection screen shown on the right it is possible to carry out the following operations with switches F3 to F6 Switch F3 Moves to next item 1 line down Switch F4 Moves to previous item 1 line up a Standard screen adjustment Switc...

Page 98: ...de ON or OFF and the standard screen is adjusted it is possible to adjust the brightness of the monitor screen day mode On the screen for items 1 it is possible to carry out the following operations with switches F2 to F6 Switch F2 Resets all adjusted values to default value Switch F3 Indicator of selected item moves 1 segment to left Switch F4 Indicator of selected item moves 1 segment to right S...

Page 99: ... monitor of the standard screen 1 On the standard screen presses switch F6 2 Select Clock Adjustment on the user menu screen then presses the switch f6 The screen switches to the time adjustment selection menu screen The following 3 items can be changed a Clock setting b 12 24 hour display mode c Daylight saving time 3 35 ...

Page 100: ...If it is not necessary to change the minute setting press switch F6 If the time has been changed always press switch F6 Switch F3 Time advances 1 minute Switch F4 Time goes back 1 minute Switch F5 Cancels change and returns to user menu screen Switch F6 Accepts change and goes to setting for 12 24 hour display mode minutes 12 24h Mode a 12h 24h Mode b 24 hour display c 12 hour display am pm Choose...

Page 101: ...light Saving Time with the switches as follows witch F3 Moves 1 item to left witch F4 Moves 1 item to right witch F5 Cancels change and returns to user menu screen witch F6 Accepts change and goes to setting for Time If the setting has been changed always press switch F6 NOTES Daylight saving time or summer time means moving the clock forward 1 hour to take advantage of the fact that the sun rises...

Page 102: ...n Thai 1 On the standard screen press switch F6 2 Select Language on the user menu screen then press switch F6 The screen switches to the language selection menu screen 3 Select the language to use for the display then press switch F6 The screen display changes to the selected language witch F3 Moves to item below witch F4 Moves to item above witch F5 Cancels change and returns to user menu screen...

Page 103: ...nu The levels that can be set are as follows E0 Default E1 Economy Adjustment 1 E2 Economy Adjustment 2 E3 Economy Adjustment 3 NOTES The higher the selection is made from E0 to E3 the better the fuel consumption becomes but the production is reduced accordingly When the machine is shipped it is set to E0 On the Economy Mode Adjustment menu screen it is possible to carry out the following operatio...

Page 104: ... switch 2 Fuel control dial 11 Hook stowage switch 3 Lamp switch 12 Winch speed selector switch 4 Sun roof wiper switch 13 Level 5 Horn switch 14 Battery disconnect switch 6 Cigarette lighter 15 Engine emergency stop switch 7 Room lamp switch 8 Emergency pump drive switch Not available for this machine 3 40 ...

Page 105: ...uring cranking Immediately after starting the engine release the key It will automatically return to the ON position HEAT position Set to this position when starting engine in cold weather When the starter key is returned to HEAT position the preheating monitor lights up Keep the key in this position until the preheating monitor flashes When the preheating monitor flashes release the key immediate...

Page 106: ...r lighting a Night position Lamps light up and monitor illumination is set to night mode b Day position Lamps light up and monitor illumination is set to day mode c OFF position Lamps go out The monitor illumination is set to day mode SUN ROOF WIPER SWITCH This switch 4 is used to actuate the wiper and window washer of the sun roof a Wiper position Wiper moves continuously b Washer position this s...

Page 107: ...ed in it will return to it s original position after several seconds so pull it out to use it If the cigarette lighter is removed the socket can be used as an 85W 24V x 3 5A power source ROOM LAMP SWITCH CAUTION It is possible to turn ON the interior cab room lamp even when starter switch is in the OFF position do not forget to turn it OFF The room lamp lights up even when starter switch is at the...

Page 108: ...possible This switch 9 is used to make it possible to carry out operation temporarily if any problem should occur in the swing parking brake system when the display shows E03 a FREE position When abnormal move switch up b NORMAL position When normal move switch down NOTES If the display shows E03 move the switch up to the FREE position to make it possible to carry out work When pushing this switch...

Page 109: ...ge to the boom or overturning of the machine After the moment limiter detects a condition that the actual load exceeds the rated load during the crane operation and interrupts it winding up boom lowering and or boom extending operation by turning this switch to ON released position must be strictly avoided It may result in boom damage or the machine overturning For hook stowage always use the Over...

Page 110: ...ck into it s stowage position in the boom top ON Keep the button pushed and operate the control lever to raise the HOOK The hook block will be winched for stowage to the boom top OFF Release the finger from the button It returns to the previous position and the auto stop function of overwind detector will be enabled NOTES When turning this switch to the RELEASE position the red lamp of the working...

Page 111: ...an accident to the machine overturning or damaging it or the hoisted load may drop which results in a serious injury or death to personnel It is advisable to avoid such a practice The purpose of the switch 12 is to use it for changing the winch speed for hoisting and lowering During such hoisting and lowering operation the pilot lamp inside the switch button lights when it is pushed to the High sp...

Page 112: ...electrical devices during inspectionmaintenance work The purpose of the switch 14 is to use to isolate the battery power to prevent electrical devices from unexpected starting during inspection maintenance work OFF The battery power is isolated and current is not supplied to all the electrical circuits ON Battery connection is resumed ENGINE EMERGENCY STOP SWITCH Use this switch 15 in case of an e...

Page 113: ... and the control levers or control pedals are touched by mistake it may lead to serious personal injury Check that the conditon of the lever is as shown in the diagram When pulling the lock lever up or down be careful not to touch the work equipment control lever The lever 1 is a device to lock the crane swing and travel control levers L LOCK position Even when levers are operated machine does not...

Page 114: ...to the direction of movement of the machine forward reverse left right When operating the travel lever always check if the track frame is facing the front or the rear When the sprocket A is at the rear the track frame is facing the front The lever 2 is used to change the direction of travel between forward and reverse See picture to the right for pedal operation a FORWARD The lever is pushed forwa...

Page 115: ... to left Boom telescoping operation c Boom retracting d Boom extending N Neutral The upper structure and boom are held in that position when they come to a stop and do not move 2 RIGHT WORK EQUIPMENT CONTROL LEVER The lever 4 is used to operate the winch and boom Winch operation e Hook raising f Hook lowering Boom derricking operation g Boom lowering h Boom raising N Neutral The hook and boom are ...

Page 116: ...djust the engine speed only by turning the fuel control dial This pedal 6 is used to adjust the engine speed or power during the crane operation a Low idling Release your foot from the pedal b Full throttle Press the pedal fully NOTES The engine speed is set by the fuel control dial and the value is given a priority thus the speed will not be slower than the value even when your foot is released f...

Page 117: ... Derrick cylinder 2 places 4 Over hoist detector Boon tip side 5 Working status lamp A Red lamp Warning lamp for load factor of 100 or more B Yellow lamp Pre warning lamp for load factor of 90 to 100 C Green lamp Working lamp for load factor of less than 90 6 Moment limiter display unit inside cab 7 Moment limiter emergency stop cancel switch Inside cab 3 53 ...

Page 118: ...ting in death or serious injury Use of this switch must be limited to the specific inspection and maintenance purpose where each sensor to detect the crane condition is checked Otherwise keep the key of the switch extracted for ordinary operations When turning ON cancel the emergency stop cancel switch always shift the crane speed to low The moment limiter is a device installed to prevent the hois...

Page 119: ...layed See Operation 2 4 10 Moment Limiter Error Causes and Actions to be Taken LIMITATION OF OPERATION DUE TO THE BLADE POSITION Indications and warning are issued against a load hoisting operation in a condition where the Blade is lowered and a load is imposed At the same time crane functions below are interrupted Indications and warnings Rated total load display in the Moment limiter will blink ...

Page 120: ...d may result in overloading or the boom to break With load factor of less than 90 When the hoisting load is less than 90 of the rated total load the working status lamp lights in green indicating normal operation status With load factor of 90 to less than 100 When the hoisting load reaches 90 of the rated total load pre warning the working status lamp changes from green to yellow and the alarm sou...

Page 121: ...ould be the reverse operation of the crane operation that caused the auto stop Perform one of the followings 1 Lower the hook and put down the hoisted load on the ground 2 Raise the boom Lower the hook so that the hoisted load will be as low as possible 3 Retract the boom 3 57 ...

Page 122: ...8 Lifting height display 24 Boom angle upper limit LED Orange 9 Fall mode selector switch 25 Boom angle Lower limit LED Orange 10 Pick Carry Stationary mode select switch 26 Working radius upper limit LED Orange 11 Boom angle upper limit switch 27 Lifting height upper limit LED Orange SETUP CANCEL 28 Pick carry mode selection LED Red 12 Boom angle lower limit switch 29 Stationary mode selection LE...

Page 123: ...witch and then press the switch again BOOM ANGLE UPPER LIMIT SWITCH AND LED ORANGE Use this switch to set or cancel the boom angle upper limit SETUP With no upper limit value set position the boom to the angle you would like and press the switch for three or more seconds The boom angle at this point is set as the upper limit At the same time the LED flashes indicating that the upper limit value ha...

Page 124: ...fy that the boom automatically stops at the set angle before performing the actual operation If the boom does not stop automatically re set the boom angle using the procedure above While the boom is within the pre warning zone or at the lower limit the warning buzzer sounds intermittently only when the boom lowering operation is attempted The limit value being set is retained in the memory even wh...

Page 125: ...m is within the pre warning zone or at the lower limit the warning buzzer sounds intermittently only when the boom lowering operation is attempted The limit value being set is retained in the memory even when the starter switch is turned to OFF position When the boom reaches the pre warning zone or stops at the upper limit with the working radius upper limit set the working radius upper limit LED ...

Page 126: ...above While the boom is within the pre warning zone or at the lower limit the warning buzzer sounds intermittently only when the boom lowering operation is attempted The limit value being set is retained in the memory even when the starter switch is turned to OFF position When the boom reaches the pre warning zone or stops at the upper limit with the lifting height upper limit set the lifting heig...

Page 127: ...plays other than those being set will not change PICK CARRY STAITIONARY MODE SELECT SWITCH AND PICK CARRY LED RED STATIONARY LED ORANGE Pick and carry operations can be unstable and dangerous Where such an operation is unavoidable see Operation 3 21 Pick Carry Operation and strictly observe rated total load for pick and carry operations correct practices and travelling posture Not observing these ...

Page 128: ...reases however this does not indicate a device failure Even when the hoisting operation is paused a swinging load will make changes in the actual load value display RATED LOAD DISPLAY SECTION The rated total load i e hook block sling instruments hoisted load applicable to the current configuration is computed based on conditions including number of wire falls boom length boom angle or working radi...

Page 129: ...SPLAY SECTION This section constantly displays the current boom angle while the crane is operating The boom angle is the angle formed between the boom and the horizontal line OVER WINDING LED RED When the hook reaches over winding condition while the crane is operating the over winding LED flashes a warning The hook winding and or boom extending is automatically interrupted This LED also flashes w...

Page 130: ...n the load factor is 110 or more NOTES Where the load factor is near 50 all the LEDs marked with 50 or below light up All the LEDs marked over 50 go out FLY JIB LENGTH 1 LED ORANGE FLY JIB LENGTH 2 LED ORANGE When the fly jib is installed the Fly jib length 1 LED automatically lights Then the fly jib length 2 LED lights if the No 2 fly jib is extended NOTES Refer to the FLY JIB for details of the ...

Page 131: ...en if the load factor is 90 to less than 100 The alarm bleeps intermittently 3 LIMIT WARNING Actual load is 100 or higher than the rated total load Load factor is 100 or higher The red working status lamp lights up The alarm bleeps continuously The hazardous operation of the boom stops automatically Load factor 100 or more LED Red lights up The Load factor 110 or more LED red lights up when the lo...

Page 132: ...er Display Unit The warning buzzer sounds only when the working envelope gets close to the set restriction value When the working envelope has been set the restriction will be as follows 1 SAFETY ZONE The appropriate working envelope restriction LED green lights up The green working status lamp lights up 2 PRE WARNING The appropriate working envelope restriction LED green flashes The alarm bleeps ...

Page 133: ... raising and boom extension operations stop automatically In the case of auto stop immediately perform the recovery operation Perform hook lowering and boom retracting operations as recovery operations THREE WINDING STOP DEVICE If you unwind the hook excessively to cause the wire cable on the winch drum to run out The Over un winding LED red flashes If the hook lowering operation is attempted the ...

Page 134: ...ble has a determined safe working load per fall Determine the number of wires according to the maximum load to be hoisted The actual number of wires used and the number of wires displayed on the moment limiter must match With this machine the hook for four two wire cables is referred to as the standard specification The last status of the set number of wires is memorized even if the starter switch...

Page 135: ...ter Be sure to set the working envelope with a safe distance from obstacles Operate the crane at low speed Be sure to verify that the boom stops at the set position after setting the boom working envelope If the boom working envelope is limited due to working space issue you can set the boom working envelope to the desired value SETTING WORKING ENVELOPE Operate the boom to the limit of the working...

Page 136: ...us accidents Use this Pick Carry Stationary mode select switch for the condition of operations 1 When a pick and carry operation is not required press this mode switch 1 and keep pressing for three or more seconds The operation mode is set to Stationary Mode and STATIONARY LED 3 lights up 2 When a pick and carry operation is required press this mode switch 1 and keep pressing for three or more sec...

Page 137: ...specified value E3H The input to angle detector is higher than the specified value Check the installation of the angle detector E4L The input to length detector is lower than the specified value E4H The input to length detector is higher than the specified value Check the installation of the length detector E5L The input to pressure sensor 5 is lower than the specified value E5H The input to press...

Page 138: ...tending and disables further operations in a condition where the hook block 1 is raised up or the boom 4 is extended until the hook block 1 comes close to the boom 4 tip and lifts the weight 3 up In such a condition the buzzer intermittently sounds to warn of over raising only when hook raising or boom extension operations are attempted When this warning buzzer sounds immediately operate the right...

Page 139: ... monitor 2 Fan switch 8 Air conditioner switch 3 Temperature control switch 9 Sunlight sensor 4 Vent selector switch 5 Auto switch OFF SWITCH This switch 1 is used to stop the fan and air conditioner NOTES Even if this switch 1 is pressed the monitor screen does not switch to the air conditioner adjustment screen 3 75 ...

Page 140: ... switch 3 is used to control temperature inside the cab The temperature can be set between 18 and 32 Press the switch to raise the set temperature press the switch to lower the set temperature The temperature is generally set at 25 The temperature can be set in stages of 0 5 Monitor display and function Monitor display Set temperature 18 0 Max cooling 18 5 to 31 5 Adjusts temperature inside cab to...

Page 141: ...ter vent Cannot be selected for automatic operation Defroster vent Cannot be selected for automatic operation Note Air blows from vents marked AUTO SWITCH This switch 5 the air flow vents and air source FRESHRECIRC air automatically selected according to the set temperature Press switch 5 then use temperature control switch 3 to set the temperature and run the air conditioner under automatic contr...

Page 142: ... and vents c When OFF switch 1 is pressed the display of temperature setting a and air flow b goes out and operation stops AIR CONDITIONER SWITCH This switch 8 is used to turn the air conditioner cooling dehumidifying and heater ON or OFF Press air conditioner switch 8 when the fan is operating when display b is shown on the display monitor The air conditioner is switched ON and starts to work Pre...

Page 143: ...witch 3 to set to the desired temperature The air flow combination of vents and selection of fresh or recirculated air is automatically selected according to the set temperature and the air conditioner is operated automatically to provide the set temperature NOTES When vent display monitor c display d or e and engine coolant temperature is low the air flow is automatically limited to prevent cold ...

Page 144: ...and airflow b are displayed on monitor 7 2 Turn air conditioner switch 8 ON 3 Press temperature control switch 3 and adjusts temperature inside the cab 4 Press vent selector switch 4 and selects the desired vents When this done the display for vent c of the display monitor changes according to the selection 3 80 ...

Page 145: ...Press FRESH RECIRC selector switch 6 and select recirculation of the air inside the cab RECIRC or intake of fresh air from outside FRESH STOPPING MANUAL OPERATION Presses OFF switch 1 Operation stops 3 81 ...

Page 146: ...he air flow When doing this check that temperature setting a and air flow b are displayed on monitor 7 2 Press vent selector switch 4 and set the vent display on the display monitor to the display shown in the diagram on the right 3 Turn air conditioner switch 8 ON 4 Adjust fan switch 2 temperature control switch 3 and FRESH RECIRC selector switch 6 to the desired positions 3 82 ...

Page 147: ...w b are displayed on monitor 7 2 Press vent selector switch 4 and set vent display on the display monitor to f or g as shown in diagram on the below 3 Press FRESH RECIRC selector switch 6 and set it to take in fresh air 4 Press temperature control switch 3 and set temperature on the display 7 monitor to maximum heating 3 83 ...

Page 148: ...r blows onto the window glass Vents C and D are fixed and cannot be adjusted NOTES When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air turn air conditioner switch 8 ON 3 84 ...

Page 149: ...erature This temperature difference is considered to be the most suitable for your health so always be careful to set the temperature properly 2 6 4 INSPECTION AND MAINTENANCE OF AIR CONDITIONER When carry out inspection and maintenance on machine equipped with an air conditioner carry out the inspection and maintenance according to the chart For details see Inspection and Maintenance 10 3 Check a...

Page 150: ...dio ON The frequency is displayed on display 7 Press again to turn the power OFF Turn the knob 1 clockwise to increase the volume press counterclockwise to reduce the volume The range for the volume is VOL 0 to VOL 40 SEL BUTTON Each time this button 2 is pressed the mode changes as follows VOL volume BAS bass TRE treble BAL balance The mode is display 7 For details of each mode see 2 7 2 Control ...

Page 151: ...possible to select one of the already preset stations Wait for 6 seconds after pressing the button and then press the button again to select the next preset station If it is impossible to receive the preset frequency the selection advances after 1 second to the next preset station PRESET STATION BUTTONS 1 2 3 4 5 6 If this button has been used to decide which stations to preset it is possible to s...

Page 152: ... FM can be preset to each Preset button NOTES It is also possible to save to the Preset button 6 by using the auto store button 5 METHOD OF TUNING 1 Press power switch 1 and display the frequency on display 7 2 Use tuning button 9 to set to the desired frequency There are two methods for tuning auto tuning and manual tuning Manual tuning Press tuning button 9 until the frequency is displayed on di...

Page 153: ...s SETTING CORRECT TIME 1 Press display selector button 4 and display the time on display 7 NOTES After 5 seconds the display 7 will return to the frequency display and the time cannot be corrected If this happens press display selector button 4 again 2 Press time adjustment button 8 to select Hour or Minute Use the H M and ADJ buttons to set to the correct time H button Adjusts the hour each time ...

Page 154: ...ide sounds during operation Take care for a risk that hearing impairment may appear after lengthy hearing the radio in a high volume If water gets into the speaker case or radio if may lead to an unexpected failure so be careful not to get water on the equipment Do not wipe the scales or buttons with solvent such as benzene or thinner Wipe with a dry soft cloth If the dirt cannot be removed easily...

Page 155: ...de the cover at the left rear of the cab FUSE CAPACITY AND CIRCUIT NAMES The table below shows the fuse system and it s capacity No Capacity Circuit name 1 10A Redundant resistance 2 30A Solenoid valve 3 15A Cigarette lighter 4 10A Window washer 5 10A Horn 6 5A Working lamp relay horn relay 7 10A Work status lamp 8 20A Working lamp 9 10A Spare 10 5A Air conditioner 11 20A Air conditioner unit 12 1...

Page 156: ... a disconnection in the fusible link Open the battery room door of the machine and check and replace If the starter motor does not turn even when the starter switch is turned to the START position there is probably a disconnection in the fusible link 1 f the battery is discharged there is probably a disconnection in the fusible link 2 n cold weather if the starter switch is turned to the HEAT posi...

Page 157: ...han 240 W equivalent to 10 A When using a large capacity electrical component contact us or our sales service agency Use this power outlet connector for use of additional electric equipment other than Maeda brand Left Connector NO M10 Behind left B pillar Right Connector NO M09 Inside cover on rear right For removable connectors contact us or our sales service agency 3 93 ...

Page 158: ...oblem occurs in the controller do not repair it yourself Please contact us or our sales service agency CHASSIS CONTROLLER The chassis controller is installed inside the rear cover at the rear of the operator s cab ENGINE CONTROLLER The engine controller is installed to the exterior frame at the rear of the engine 3 94 ...

Page 159: ... and do not let go until the automatic lock catch is locked When closing the front window the window will move quicker under is own weight Hold the grips securely with both hands when closing it It is possible to stow pull up the front window in the roof of the operator s compartment OPENING 1 Stop the machine on level ground stow the crane completely then stop the engine 2 Set lock lever 1 secure...

Page 160: ...r of the cab securely to lock the window 6 Check that lever B is securely at the LOCK position NOTES The lock is engaged if the arrow on lock case F matches the position of the arrow on lever B Check visually If the arrow on lock case F does not match the position of the arrow on lever B the lock is not engaged Repeat the operation in Step 5 to engage the lock 3 96 ...

Page 161: ...stow the crane completely then stop the engine 2 Set lock lever 1 securely to the LOCK position L 3 Grip left and right handles A and pull down lever B to release the lock 4 Grip handle C at the bottom of the front window with your left hand and handle D at the top with your right hand push to the front then lower slowly 3 97 ...

Page 162: ...d right lock catches G and engage the lock 6 Check that lever B is securely at the LOCK position NOTES The lock is engaged if the arrow on lock case F matches the position of the arrow on lever B Check visually If the arrow on lock case F does not match the position of the arrow on lever B the lock is not engaged Repeat the operation in Step 5 to engage the lock 3 98 ...

Page 163: ...seat 3 2 Insert the top right of the glass into the groove in seat 4 3 Push lock 2 to the free position F Tooth A will come up so push the glass against it then release lock 2 and secure the top of the glass When lock 2 is released it will return to LOCK position L and tooth A will go down CAUTION When stowing the glass lock it securely and check that there is no play If there is play or the lock ...

Page 164: ...erson before opening or closing the door Door Lock When closing the door pull the handle back to remove lock 3 and then pull the door to the front 2 14 EMERGENCY ESCAPE HAMMER If it is necessary to break the window glass with hammer be extremely careful not to injury yourself on the flying pieces of broken glass To prevent injury remove the broken pieces of glass remaining in the frame before esca...

Page 165: ...n the right 1 Door of operator s cab 2 Fuel tank filler port 3 Engine hood OPENING AND CLOSING CAPS WITH LOCK For fuel tank filler port Opening the Cap 1 Insert the starter switch key into the key slot 2 Turn the key clockwise align the key groove with mark 1 on the cap then open the cap Position A OPEN Position B LOCK Locking the Cap 1 Turn the cap until tight and then insert the starter switch k...

Page 166: ...switch key into the key slot 2 Turn the key counterclockwise and open the cover by pulling the cover grip Position A OPEN Position B LOCK Locking the Cover 1 Close the cover and insert the starter switch key into the key slot 2 Turn the key clockwise and take the key out 3 102 ...

Page 167: ...od open Except for checking purpose keep the engine hood closed during operation Always keep the engine hood locked except when opening it 1 Open 1 the engine hood 2 While pressing the engine hood opening knob 1 open the hood 2 3 After opening the hood secure the hood support lever 3 at the hood securing position 4 To close the hood 2 remove the hood support lever 3 and secure the lever to the lev...

Page 168: ...h to hold the door open 3 To close door 2 lift the rod 3 and remove from hitch then close the door 2 18 MAINTENANCE DOOR ON REAR LEFT When carrying out inspection and maintenance inside the door always use the stopper to hold the door open 1 Insert fingers to door pull 1 and open door 2 2 After door 2 is open insert rod 3 into hitch to hold the door open 3 To close door 2 lift the rod 3 and remove...

Page 169: ...r open Always keep the door locked except when opening it 1 Remove stowage rope 3 from rope holder 4 2 Lift the cover handle 1 3 While lifting the cover 2 pull the cover toward you and lower the cover 4 Close the cover 2 so that the turnback at the end of the cover 2 is hooked 5 Hang the stowage rope 3 to the rope holder 4 3 105 ...

Page 170: ...t it is possible to read it at any time 2 21 CUP HOLDER This is on the left side of the operator s cab 2 22 GREASE PUMP HOLDER There is a grease pump holder inside the maintenance door on left rear side When grease pump is not used store it in this holder 2 23 ASHTRAY This is on the left side of the operator s cab Always extinguish your cigarette before putting it in the ashtray and then be sure t...

Page 171: ... during operation Fit the seat belt so that it is not twisted This seat belt has a wind in device so it is not necessary to adjust the length FASTENING SEAT BELT Hold grip 2 and pull the belt out from wind in device 1 check that the belt is not twisted then insert tongue 3 into buckle 4 securely When doing this pull the belt lightly to check that it is properly locked REMOVING SEAT BELT Press butt...

Page 172: ...r cracks on the fuel hose or fuel hose connections Remove any flammable materials from around the battery engine muffler turbocharger or other high temperature engine parts Leakage of fuel or oil will cause the machine to catch fire Check carefully be sure to repair any problem or contact us or our sales service agency Check the items shown in this section as routine surveillance before starting t...

Page 173: ...orking lamp for cracks excessive deformation and contamination etc If you find any abnormalities repair them If dirty clean it Check for sagging electrical wiring loose connections and burn traces If you find any abnormalities repair them CHECKING WIRE ROPES See Operation 4 Handling Wire Cables for wire cables Check the wire cables for damage deformation wear twists kinks corrosion etc If you find...

Page 174: ...or s view CHECKING AROUND OPERATOR S CAB Check windshields for dislocation or damage and cracks or impairments in window panes If you find any abnormalities repair them If the windshields are broken stop your work and repair them immediately Check the seat belt and mounting bracket for abnormalities If any damage is discovered replace them with new ones Verify that all operation levers travel leve...

Page 175: ...carefully to release the pressure 1 Stop the machine at leveled location 2 Open maintenance door on right rear side and set rod into hitch to hold the door open 3 Check the cooling coolant level in the sub tank 1 to be between FULL and LOW marks 4 If the coolant level is lower than the LOW level use the following procedure to refill with tap water 1 Remove the cap of the sub tank 1 and fill water ...

Page 176: ...orate faster A very low level of oil may cause the engine to burn out 1 Stop the machine at leveled location 2 Open engine hood and securly lock to hold the door with hood support bar 3 Remove the dipstick G and wipe the oil off with a cloth 4 Fully insert the dipstick G into the gauge guide and then remove it 5 If the oil level is between the H and L marks on the dipstick G the oil level is norma...

Page 177: ...ant and lubricants according to ambient temperatures for which fuel to be used Be careful not to let any foreign substance go into the filler opening when refueling 1 Stop the machine at leveled location 2 Turn the starter switch to the ON position and check that the fuel level gauge 1 on the monitor panel for fuel level After checking turn the starter switch back to the OFF position 3 If fuel is ...

Page 178: ...has not returned to the tank For details of traveling posture see Operation 3 6 Machine Traveling Posture Be careful not to let dust go in from the filler opening when refilling with oil 1 Stop the machine at leveled location 2 Put the machine in the traveling posture shown in the diagram on the right 3 Turn the starter switch to the OFF position 4 Within 15 seconds after stopping the engine move ...

Page 179: ...de tank 9 Set plate 3 to the center of the cap and fix with bolt 2 10 Set cover 1 above the hydraulic oil tank CAUTION Do not add oil above the H line This will damage the hydraulic circuit or cause the oil to spurt out If oil has been added above the H level the procedure for draining oil is as follows 1 Swing the upper structure and stop it so that the drain plug P under the hydraulic oil tank w...

Page 180: ...s appeared clean or replace the air cleaner element immediately For details of the method of cleaning the air cleaner element see Maintenance 10 3 Irregular Maintenance Checking cleaningreplacement Air Cleaner Element 3 After checking cleaning or replacing the air cleaner element press the knob of dust indicator 1 to return the red piston to it s original position 3 116 ...

Page 181: ...he water separator forms one unit with fuel pre filter 1 Place a container to catch drain water 1 Stop the machine at leveled location 2 Open engine hood and surely lock it open with hood support bar 3 Check the transparent cap 2 for any water or dust in the transparent cap 2 4 It is possible to judge the water level and amount of sediment by looking through transparent cap 2 if there is any water...

Page 182: ...a suitable amount of grease When doing this be careful not to let the grease get stuck to the drain valve water drain port 7 or drain valve thread 8 6 Tighten drain valve 4 by hand until it contacts the bottom of transparent cap 2 7 Remove the fuel container 8 Set valve 5 to the open position O DRAIN WATER AND SEDIMENT FROM FUEL TANK Plase a container to catch drain water 1 Swing upper structure s...

Page 183: ...r pay attention and check the electrical wiring of the battery engine starter and alternator Be sure to check that no inflammable materials have accumulated around the battery If any are found remove them immediately CHECKING WORKING LAMP Check that the working lamps and lamps inside the instruments light up properly Check also that there is no dirt or immediately clean If any lamp does not light ...

Page 184: ...seat back to the upright position Pull up lever 2 and set the backrest to a position that is comfortable for operation then release the lever Sit with your back against the seat backrest when adjusting If your back is not against the backrest the backrest may suddenly move forward C Adjusting Armrest Angle Armrest 3 can be made to spring up by hand approx 90 In addition by turning the dial 4 at bo...

Page 185: ...g in the left rear end of the machine is visible Fix the mirror as shown in the figure in the right Dimension E 170 mm Fix the mirror stay 1 to allow that the mirror position extend fully When fine adjustment of the mirror is not easy loosen the bolt 2 for the mirror or bolt 3 for stay mount for easy movement Tightening torque of bolt 2 15 7 19 6 Nm 1 6 2 0 kgfm Adjust the mirror angle so that the...

Page 186: ... mount for easy movement Tightening torque of bolt 4 15 7 19 6 Nm 1 6 2 0 kgfm Adjust the mirror angle so that the right front part of the machine body is reflected as shown in the figure right Mirror C Position of this mirror should be adjusted so that a person standing in the right side of the machine is visible Fix the mirror as shown in the figure in the right When fine adjustment of the mirro...

Page 187: ... L 2 Check that each control lever and pedal is at the Neutral position If the control levers and pedals are not being touched they will be at the Neutral position 3 Insert the key in starter switch 2 turn the key to the ON position and then carry out the following checks If a password has been set the input display screen will be displayed on the monitor screen After inputting the password press ...

Page 188: ...creen Engine oil temperature gauge 6 Engine oil temperature monitor 7 Fuel gauge 8 Fuel level monitor 9 Hydraulic oil temperature gauge 10 Hydraulic oil temperature monitor 11 3 If the hydraulic oil temperature gauge is out or caution lamp 12 stays lit up red immediately check the item that lights up red 4 If the maintenance interval has passed maintenance interval monitor 13 lights up for 30 seco...

Page 189: ...engine as soon as possible CHECKING OF ENGINE ACCELERATION AND DECELERATION When stopping the machine during the operation check that there is no irregular engine speed or that the engine does not stop suddenly Check also that the engine speed rises smoothly when the fuel control dial is turned to the full MAX Carry out these checks in a safe place watching out for any potential surrounding danger...

Page 190: ...pment control lever is moved to the RETRACT position pull backward When doing the above check for any abnormal sound emitted by part of the boom or from the boom telescoping cylinder If you find any abnormalities repair them 3 Verify that the hook is wound down smoothly when the right hand work equipment control lever is moved to the HOOK LOWERING position push forward Also verify that the hook is...

Page 191: ...ode is displayed at the RATED TOTAL LOAD display on the display panel 4 Start the engine and operate the crane as follows to verify whether the moment limiter correctly displays the value Crane Operation and Displayed Parameter Value Displayed on Moment Limiter Displayed boom length with the boom length at minimum 4 6 m Displayed boom length with the boom length at maximum 15 3 m Displayed working...

Page 192: ...paces be particularly careful to ensure there is sufficient ventilation CAUTION If it is hard to start the engine due to low ambient temperature see Operation 3 2 2 Starting in cold weather for the engine starting operation Do not try to start the engine with the fuel control dial set near the full engine rotation Otherwise the engine parts may be damaged Do not keep the starter motor rotating con...

Page 193: ...tch 3 The key will automatically return to ON position 5 Keep the engine idle for the initial 15 seconds right after it has been started and do not operate any control lever or the fuel control dial during that time 6 Check that the battery charge monitor 4 engine oil pressure monitor 5 and engine oil level monitor 6 are OFF 3 129 ...

Page 194: ...ventilation Be sure to have engine hood and other covers closed during operation except for inspection time CAUTION Do not try to start the engine with the fuel control dial set near the full engine rotation Otherwise the engine parts may be damaged Do not keep the starter motor rotating continuously for more than 20 seconds If the engine fails to start wait for about 2 minutes and repeat from Ste...

Page 195: ...on 4 When engine preheating monitor 4 goes OFF turn the key in starter switch 3 to the START position to start the engine 5 When the engine starts release the key in starter switch 3 The key will automatically return to ON position 6 Keep the engine idle for the initial 15 seconds right after it has been started and do not operate any control lever or the fuel control dial during that time 7 Check...

Page 196: ...rol dial When the turbocharger protect function is actuated the engine speed is held at less than 1150 rpm even if the fuel control dial is operated When the turbocharger protect function is canceled the engine speed is set to the speed for the position of the fuel control dial The relationship between the length of time of actuating the turbocharger protect function and the temperature of the eng...

Page 197: ...C is white If the warm up operation for the hydraulic equipment is not carried out thoroughly and the machine is moved the reaction of the control levers and pedals will be slow and the movement may not be what the operator intended Always warm up the hydraulic equipment In particular in cold areas always warm up the hydraulic equipment thoroughly There are two types of warm up operation warm up t...

Page 198: ...lowing operations and checks 1 Wait until the automatic warm up operation is cancelled At the engine coolant temperature of 55 automatic warm up operation is cancelled and engine speed returns to normal low idling 2 Check that the engine coolant temperature monitor 1 displays the correct temperature A Display when temperature is correct Monitor background C is blue B Display when temperature is lo...

Page 199: ... cylinders and between the pump and motor but also for the control circuits Do not carry out the operation just for one cylinder or motor or the operation just in one direction Carry out the operation in all directions for all the crane swing and swing 1 Check that the engine coolant temperature monitor 1 displays the correct temperature A Display when temperature is correct Monitor background C i...

Page 200: ...ull backward position and raise the hook adequately so that it does not touch the ground 7 Operate right work equipment control lever 4 slowly to RAISE side pull toward you Operate the lever to the stroke end and hold it in position for 30 seconds During that task operate the Right work equipment control lever 4 to HOOK LOWERING push forward position and lower the hook adequately to avoid over win...

Page 201: ...w Monitor background C is white If the hydraulic temperature monitor is not displaying the correct temperature it is displaying low temperature repeat Steps 6 to 10 until the display is the correct temperature When hydraulic oil meter indicates high temperature above E point set engine speed to low idling until the temperature decreases to D E area 12 Check that engine coolant temperature monitor ...

Page 202: ...nitor 13 Displays appropriate level 14 Check for abnormal exhaust gas color noise or vibration If any problem is found contact us or our sales service agency CAUTION When it is extremely cold under 0 to warm up whole hydraulic equipment follow the procedure 15 even if the hydraulic oil temperature meter indicates D E range 15 Turn fuel control dial 3 to the full speed MAX position repeat Steps 6 t...

Page 203: ...range speed before operating 17 Before starting operations repeat the following operations slowly 3 to 5 times to circulate warm oil through the control circuits Boom derricking operation RAISE D to from LOWER C Boom telescoping operation EXTEND A to from RETRACT B Winch operation RAISE E to from LOWER F Swing operation Left G to from Right H Travel Lo operation FORWARD to from REVERSE Travel Lo o...

Page 204: ...display is the correct temperature A Display when indication of 20 102 is correct Monitor background C is blue B Display when temperature is low Monitor background C is white If the hydraulic oil temperature monitor displays the correct temperature the hydraulic equipment warm up operation is completed After confirming that the hydraulic oil temperature monitor displays the correct temperature car...

Page 205: ...is low Monitor background C is white 2 Push working mode selector switch 14 of the machine monitor to select the working mode to be used For details of the procedure for selecting the working mode see Operation 2 1 6 Monitor Switches portion Working mode monitor display P mode For heavy duty operations E mode For operations with emphasis on fuel economy L mode For operations requiring fine control...

Page 206: ...ncy If the engine has overheated do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually and then stop it 1 Turn fuel control dial 2 at the low idle position MIN and run the engine at low idling for 5 minutes to cool down gradually 2 Turn the key in starter switch 1 to the OFF position and stop the engine 3 Remove the key from starter switch 1 3 142 ...

Page 207: ...grade the functions of the engine and crane shortening their life Perform the breaking in for the first 100 hours time displayed on the service meter Pay attention particularly to the following during the breaking in period Be sure to carry out the engine and hydraulic equipment warm up operations after the engine has started See Operation 3 3 Operations after Starting Engine Start the engine at l...

Page 208: ...in the traveling posture as shown in the figure in the right when travel to and from an operation site or a transportation depot Retract the boom fully Lower the boom fully Stow the hook block to it s designated stowage position regular stowage position Always direct the sprocket A backward TRAVELING IN THE COURSE OF OPERATIONS Keep the machine in the traveling posture as shown in the figure on th...

Page 209: ...eceleration is being used if the travel lever or travel pedal are operated the engine speed will suddenly rise so be careful when operating the travel lever or travel pedal The accelerator pedal should only be used to control the crane operation while the machine is stationed During traveling operation use of this pedal is strictly prohibited otherwise it may cause an accident due to an operation ...

Page 210: ...her by pulling lever 3 back slowly or by stepping on the rear part of pedal 4 slowly NOTES Check that the travel alarm sounds properly If the travel alarm does not sound please contact us or our sales service agency In cold temperature if the machine travel speed is not normal thoroughly perform the warming up operation In addition if the undercarriage is clogged with mud and the machine travel sp...

Page 211: ...by pushing lever 3 forward slowly or by stepping on the front part of pedal 4 slowly NOTES Check that the travel alarm sounds properly If the travel alarm does not sound please contact us or our sales service agency In cold temperature if the machine travel speed is not normal thoroughly perform the warming up operation In addition if the undercarriage is clogged with mud and the machine travel sp...

Page 212: ...STOPPING MACHINE Avoid stopping suddenly Give yourself ample room when stopping Put the left and right travel levers 3 to the NEUTRAL position and then stop the machine 3 148 ...

Page 213: ...lows STEERING THE MACHINE WHEN STOPPING When turning to the left push the right travel lever forward The machine turns to the left when travelling forward Pull the lever backward and the machine turns to the left when travelling backward A Forward left turn B Reverse left turn NOTES When turning to the right operate the left travel lever in the same way CHANGING DIRECTION OF THE MACHINE When turni...

Page 214: ... using counter rotation spin turn to turn left pull the left travel lever back and push the right travel lever forward NOTES When using counter rotation spin turn to turn right pull the right travel lever back and push the left travel lever forward 3 150 ...

Page 215: ...machine is safe and sound the horn When the auto deceleration has been actuated and the engine speed is low if the control lever is operated the engine speed will suddenly rise so be careful when operating 1 Operate left work equipment control lever 1 to swing the upper structure A Left swing B Right swing When not operating to swing place the left work equipment control lever 1 to N neutral posit...

Page 216: ...Inching operation B mode Not available for this machine ATT mode Not available for this machine 1 If working mode selector switch 1 is pressed the working mode selection screen is displayed on the monitor 2 Press switches F3 of F4 at the bottom of the screen or the working mode selector switch to select the appropriate mode 3 After selecting the desired mode press switch F6 to accept the change Th...

Page 217: ...miter computes the load using the value of 4 falls thus even though the actual load reaches pre warning zone no pre warning or warning is provided Consequently when the rated total load exceeds the allowance of the 2 falls the wire cable may break When you over hoist the hook the over hoist detector actuates to sound the buzzer and stop hook raising When the warning buzzer sounds immediately relea...

Page 218: ... Use the horn switch and toot the horn to warn danger to persons nearby when necessary during crane operations 3 154 ...

Page 219: ... the hook block is released from the regular stowage position the hook block may swing wildly and damage other components around it Pay sufficient attention to maintaining safe conditions around the hook block Perform the following operations before operating the crane 1 Set lock lever 1 to the FREE position 2 Turn fuel control dial 2 to low idling position MIN 3 Operate the right work equipment c...

Page 220: ...d 4 above alternately so that the boom is slowly raised to the position where the hook block 4 comes perpendicular to the stowage position in the front of the crane upper structure When hook block 4 is released from stowage rope 5 before the boom is sufficiently raised to the correct position hook block 4 may swing wildly and cause damage to the machine or serious injuries to people 6 Remove hook ...

Page 221: ...rd so that the hook block is hoisted Here take care not to over hoist the hook block Over hoisting will cause Over hoisting warning situation 2 Operate the right work equipment control lever to BOOM LOWER position push right so that the boom is lowered Be careful not to over lower the hook block to avoid it laying on the ground 3 Repeat the practices of 1 and 2 above alternately so that the crane ...

Page 222: ...over lower the hook block an action that will result in it laying on the ground That may result in irregular winding of the wire cable to the drum During the winch operation always avoid returning the lever to the neutral position abruptly which loosens the wire cable and may result in irregular winding of the wire cable to the drum 3 14 1 NORMAL HOOK RAISING LOWERING OPERATION Operate the right w...

Page 223: ... of the machine or dropping of the load resulting in death or serious injury NOTES At the boom Derricking operation the actual load indication in the moment limiter may make insignificant changes due to pressure change in the derrick cylinder In a condition where the actual load indication in the moment limiter is 0 5 tons or more the high speed mode is not available even when the winch speed sele...

Page 224: ...switch box as follows ON Keep the button pushed and move the right hand work equipment control lever to the HOOK RAISING pull backward position The hook block will be winched for stowage to the boom tip The pilot lamp inside the switch lights at this time OFF Release the finger from the switch It returns to the previous position and the auto stop function of over hoist detector will be enabled The...

Page 225: ...mely careful so that the load weight will not be exceeded with the boom in the lowest position when working by derricking the boom Move right hand work equipment control lever 1 as follows Lower Push the lever toward outside right Neutral Release the lever The lever goes back to the NEUTRAL position and the boom derricking stops Raise Pull the lever toward you left NOTES Adjust the boom derricking...

Page 226: ... block is raised or lowered while telescoping the boom Perform the winch operation at the same time to adjust the hook block height When the boom is maintained extended for long periods the boom slightly retracts due to the temperature change in the hydraulic oil In this case extend the boom as needed Perform the left work equipment control lever 1 as follows Extend Push the lever forward Neutral ...

Page 227: ...ver Such practices must be carried out with hook raising operations Operate left hand work equipment control lever 1 as follows Left Push the lever toward outside left Neutral Release the lever The lever returns to the NEUTRAL position and the swing stops Right Pull the lever toward inside right NOTES Adjust the crane swing speed with left hand work equipment control lever 1 and the stroke of acce...

Page 228: ...ble for proper control of the operation speed WHERE THE OPERATION SPEEDS ARE UNVARYING Set the fuel control dial 1 adequately to the operation speed a Low idling MIN The position that the dial is turned counterclockwise left to the end b Full throttle MAX The position that the dial is turned clockwise right to the end WHERE THE OPERATION SPEEDS ARE VARYING 1 Set the fuel control dial 1 to the mini...

Page 229: ...condition it does not enter the hook block stowage mode and may result in damage being caused to the top of the hook block the boom or wire cables CAUTION Prior to stowing the hook block stop the hook block swinging Be careful not to over lower the hook block an action that will result in it laying on the ground Doing so may result in irregular winding of the wire cable to the drum The boom retrac...

Page 230: ...erate left hand work equipment control lever 2 to the LEFT push outside position or the RIGHT pull toward you position so that the boom comes to the center of the machine NOTES By carrying out Steps 1 to 4 the boom stowage process will be complete Next hook block 4 will be stowed as follows 5 Move right hand work equipment control lever 1 to the HOOK RAISING pull backward position and continue rai...

Page 231: ...t hand work equipment control lever in the HOOK RAISING position for about one second after the hook block is stowed in the boom tip NOTES When turning this switch to the Stowage position the red lamp of the working status lamp will light up When the winch is hoisted while this switch is pushed the winch speed is slower however it is not a winch failure NOTES The figure at right shows the correct ...

Page 232: ...lock swinging Be careful not to over lower the hook block an action that will result in it laying on the ground That may result in irregular winding of the wire cable to the drum The boom retraction operation also leads to hook block lowering condition Also boom lowering results in the hook block being lowered To avoid it laying on the ground raise the hook block at the same time 1 Operate left ha...

Page 233: ...lock 4 may damage other components around 4 Remove wire cable 5 for the hook block stowage from hanger 6 5 Fasten hook block 4 to wire cable 5 for the hook block stowage 6 Move right hand work equipment control lever 1 to the LOWER push outside position and lower the boom until it stops NOTES During this operation raise up hook block 4 occasionally to take up the wire cable slack Be careful so tha...

Page 234: ... HOOK RAISING pull backward position to raise hook block 4 up slowly and precisely to tension wire cable 5 NOTES During this operation avoid over raising hook block 4 Otherwise stowage wire cable 5 may damage the regular stowage position and around it in the front of the upper structure of the crane when over wound 3 170 ...

Page 235: ...os and don ts in this section DON T OPERATIONS WITH SWING FORCE Do not draw in or lift the load with a swing operation DON T OPERATIONS WITH DERRICKING FORCE Do not draw in or lift the load with a boom derricking operation DON T PULL SIDEWAYS DRAW IN OR HOIST DIAGONALLY Pulling sideward drawing in or hoisting diagonally applies unreasonable force on the machine It not only damages the machine body...

Page 236: ...l of performance can cause accidents In particular crane operations must be carried out according to the rated total load chart DON T WIND WIRE BY FORCE Be careful not to hook the wire cable over a tree or steel beam while working If it gets stuck on something do not force by winding the wire Untangle and then wind the wire PICK AND CARRY OPERATION Pick and carry operations are very dangerous and ...

Page 237: ...rane operations on a slope If you absolutely have to do so place some earth fill B on the slope to make the ground level and hard and to prevent the machine from turning over then place the machine on the ground Always check that the machine is level using the level gauge on the left side of operator s seat 3 173 ...

Page 238: ...hey create a risk of the machine overturning Always survey the road surface or the ground prior to operations and arrange a person to direct an appropriate path to take in dangerous or low visibility areas Slopes soft surfaces such as damp ground ground with many barriers rough surfaces such as riverbeds or ground with many bumps that need to be navigated over Near a deep gutter or a shoulder of a...

Page 239: ...and PICK CARRY LED 2 lights up 2 See Operation 3 16 Boom Telescoping Operation and retract the boom to 10 1 meters 3 section or less accordingly 3 See Operation 3 14 Hook Raising Lowering Operation and lower the hoisted load until it nearly touches the ground NOTES If the boom length exceeds 10 2 meters and the Searcher hook mode is activated and where the Pick Carry Stationary mode select switch ...

Page 240: ... away from other machines or structures to avoid collisions 1 See Operation 3 7 Starting Moving Stopping Machine and Operation 3 8 Steering Machine for travelling the machine 2 See Operation 3 14 Hook Raising Lowering Operation and Operation 3 15 Boom Derricking Operation for crane operation In this operation keep the hoisted load at a height where it is almost touching the ground to prevent it sh...

Page 241: ...d result a serious hazard Any leveling operations other than in the basic posture may cause the machine to tip over or damage to the wire rope which triggers a serious accident SAFETY PRECAUTIONS FOR GROUND LEVELING In the condition that the boom is full lowered it s end exceeds the Blade end by 177cm It is essential to ensure that no obstacles lie ahead Else the boom may hit an obstacle and cause...

Page 242: ...oment limiter will blink and indicate bld Buzzer sounds intermittently The red lamp of the rotary lamp lights Functions to be interrupted Winch hoisting Winch lowering Boom derricking Boom extending When a certain loading is applied to the Blade in addition to that of a load that is hoisted the above conditions continue Either clear the Blade from the ground or lowering the hoisted load on the gro...

Page 243: ...denly move which may cause a serious accident Before standing up from the operator s seat always set the lock lever securely to the LOCK position 1 Set left and right travel levers 1 to the Neutral position N The machine stops 2 Release accelerator pedal 2 to rotate the engine at low idling speed 3 Lower down the blade onto the ground 4 Set lock lever 3 securely to the LOCK position L Stop the eng...

Page 244: ...eck for any leakage of oil or coolant If a leakage or an abnormality is found repair it 2 Refill the fuel tank 3 Check around the engine compartment and battery for paper and debris Clean out any paper and debris to avoid a fire hazard 4 Remove all the mud and water from the undercarriage of the machine 3 24 3 LOCKING Always lock the following places 1 Door of operator s cab 2 Fuel tank filler por...

Page 245: ... as possible If you have to travel over the obstacles be sure to take the travelling posture to lower the center of gravity and reduce the travelling speed as much as possible so that the machine will go over the obstacles at the center of the crawlers NOTES See Operation 3 6 Machine Travelling Posture for the machine travelling posture CAUTIONS IN HIGH SPEED TRAVELLING On uneven roadbeds such as ...

Page 246: ...er water and water will be thrown up by the radiator fan This may cause the fan to break Be extremely careful when driving the machine out of water Do not drive the machine in water deeper than center of carrier roller 1 Supply grease to the parts which have been under water for long periods until the used grease is projected out of the bearings 3 182 ...

Page 247: ...mpt to turn around it or traverse it When possible use a level route and make a detour to avoid the slope to increase safety Keep travelling in a manner so that the machine can be stopped whenever it slips or becomes unstable When travelling down steep hills use the travel lever and accelerator pedal to keep the travel speed low When travelling down a steep hill of more than 10 with sprocket A sid...

Page 248: ... 0 dia 10 67 7KN No 4 boom retracting wire cable IWRC 6 Fi 29 0 0 dia 8 43 3KN No 5 boom retracting wire cable IWRC 6 Fi 29 0 0 dia 6 24 3KN BENCHMARK FOR REPLACING WIRE CABLES A wire cable undergoes wear and tear over time Prompt replacement is required if any of the following have occurred to the wire cable 1 Percentage of snipped wires to total wires except filler wires in outer strands exceeds...

Page 249: ...2 Waviness width is 4 3d or more in a distance within 25 times of nominal diameter d 3 The minimum diameter is 2 3 or less of the maximum diameter due to local pressure and being flattened 4 Core wire or wire core projects 5 Excessively curved 6 Basket like deformation 7 A strand sinks inside 8 One strand or more is slack 9 Wires project excessively 5 The cable shows some abnormality at the termin...

Page 250: ...eed The load to one wire rope fall must be within 1220 kg The table below shows the hook block types wire rope falls and the rated total load in each condition Type of Hook Blocks For 2 or 4 Falls Common For 2 or 4 Falls Common For 1 fall Exclusive Number of Wire Falls 4 2 1 Wire Rope Configuration Rated total load 4900 kg 2450 kg 1220 kg Hook weight 90 kg 90 kg 20 kg 3 186 ...

Page 251: ...and how many times the cable is twisted 2 Operate the left hand work equipment control lever to the RETRACT position pull backward to retract the boom to lower the boom fully 3 Move the right hand work equipment control lever to the LOWER position push outside to lower the boom to approximately 20 4 Move the right hand work equipment control lever to the HOOK LOWERING position push forward to un h...

Page 252: ...from the direction the hook block is twisted to and which you checked in the step 1 opposite direction from the one the wire cable tries to go back to naturally when you release your hand from the wedge socket and install the wire cable 8 Start the engine and move the right hand work equipment control lever to the RAISE position pull toward you to increase the boom angle to its maximum 9 Operate t...

Page 253: ...the hook block for several times 11 Tidily spool up the wire cable into the winch drum with some tension applied to the cable 12 Repeat the above procedure until the hook is no longer twisted If the wire cable is still twisted after performing the procedure above change with a new wire cable 3 189 ...

Page 254: ...able local laws and regulations observe these laws and regulations for safe transportation If not contact us or our sales service agency TRANSPORTATION MEASURE Take road width height and weight into consideration in determining the transportation route To determine the transportation measure see the weights and dimensions shown in Specifications 1 Main Specification Table 3 190 ...

Page 255: ...rward involves overturning hazard The operator must be on the back side of the truck Always unload the machine by moving forward Moving backward involves overturning hazard The operator must be on the back side of the truck Loading Unloading the machine involves danger Be extremely careful Select flat and solid ground for loading unloading the machine Keep sufficient distance from the ground shoul...

Page 256: ...arge amount under the weight of the machine put blocks under the ramps to prevent them from bending 4 Start the engine Warm the engine up fully 5 Set the lock lever to FREE position F 6 Operate blade lever to raise the blade 7 Turn the travel speed selector switch 5 to low speed travel range Lo monitor lights up Press travel speed selector switch 5 to switch the travel speed range The travel speed...

Page 257: ...el slowly Only operate the travel lever while on the ramps Do not operate any other lever 11 When the machine travels over the rear wheels of the trailer it becomes unstable drive slowly and carefully Never operate the steering 12 At the moment the machine passes the rear wheels it tilts backward be careful not to let the crane hit the trailer body Drive the machine backward to the specified posit...

Page 258: ... 3 Stop the engine and then remove the key from the starter switch 4 Close all doors windows and covers Lock covers caps and doors fitted with locks 5 Place blocks under both ends of the tracks to prevent the machine from moving during transportation and secure the machine with chains or wire ropes of suitable strength Be particularly careful to secure the machine in position so that it does not s...

Page 259: ...Remove the chains and wire ropes fastening the machine 5 Start the engine Warm the engine up fully 6 Set the lock lever to FREE position F 7 Operate blade lever to raise the blade 8 Turn the travel speed selector switch 5 to low speed travel range Lo monitor lights up Press travel speed selector switch 5 to switch the travel speed range The travel speed range Lo Hi is displayed on the travel speed...

Page 260: ... specifications when lifting up the machine Also avoid the slinging wire cables touching the machine body during the lift Wire cable Breaking load 18 7 t or more 6 37 dia 18 2 0 m or more Shackle Using load 7 0 t or more Nominal size 34 SC type When the machine is lifted in its boom lowered posture make sure that the hook block is in the regular stowage position For details see Operation 3 19 2 Cr...

Page 261: ...han 60 degrees and lift up slowly NOTES After lifting the machine just clear of the ground check the condition of the hook and the lifting posture Verify that there has been no change in posture caused by the leakage from the hydraulic circuit on the derricking cylinder head side when the machine is hoisted When the machine in the standard configuration is lifted it leans about 3 5 degree backward...

Page 262: ...ackles into the two brackets on both the left and right sides of the boom other than as specified below must never be attempted for lifting the machine If such a practice is unavoidable please contact us or our sales service agency CAUTION Use two wire cables and two shackles of the same specifications when lifting up the machine Wire cable Breaking load 36 t or more 6 37 dia 25 5 0 m Shackle Usin...

Page 263: ...ondition of the hook and the lifting posture Verify that there has been no change in posture caused by the leakage from the hydraulic circuit on the derricking cylinder head side when the machine is hoisted When the machine in the standard configuration is lifted it leans about 0 backward and about 3 5 toward the operator s compartment side This leaning angle may vary slightly in accordance with t...

Page 264: ...skin wash it off with large amounts of fresh water and see a doctor at once When changing the coolant or when handling coolant containing antifreeze that has been drained when replacing the coolant or repairing the radiator you should employ a specialized contractor or contact us or our sales service agency Antifreeze is toxic Do not let it flow into drainage ditches or spray it onto the ground su...

Page 265: ...rriage from freezing and making it impossible for the machine to move on the following morning observe the following precautions Remove all the mud and water from the machine body In particular wipe the hydraulic cylinder rods clean to prevent damage to the seal caused by mud dirt or drops of water from getting inside the seal Park the machine on hard dry ground If this is impossible park the mach...

Page 266: ...ve ventilation and prevent gas poisoning During storage operate and move the machine for a short distance once a month so that a new film of oil will coat moving parts At the same time also charge the battery When operating the crane wipe off all the grease from the hydraulic cylinder rods Operate the air conditioner for 3 to 5 minutes once a month to lubricate all parts of the air conditioner com...

Page 267: ... pump and tighten it 3 Start the engine NOTES When doing this do not turn the starter motor continuously for more than 20 seconds If the engine does not start wait for at least 2 minutes then try again Perform this operation a maximum of 4 times 8 2 PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures Some noise from around valves when boom is fully retracted and the ...

Page 268: ... rope NOTES Permissible towing force for this machine is 50 400N 5 140kg Do not tow applying a bigger force than this If pulling the machine out when it is stuck in mud or when towing a heavy object with the machine pass wire cables for towing lengthwise through the track frame as shown in the figure on the right Put wooden blocks between the wire cables and the machine to prevent the cables causi...

Page 269: ... from the ground normally the negative terminal When installing install the positive terminal first If a tool touches the positive terminal and the chassis there is a danger that it will cause a spark so be extremely careful If the terminals are loose there is danger that the defective contact may generate sparks that will cause an explosion Install the terminals securely When removing or installi...

Page 270: ...nd remove metal fittings 9 8 Rmove the battery from the machine INSTALLATION 1 Place the battery in the specified position 2 Fix battery securely with metal fittings 9 and mounting nuts 8 Mounting bolt tightening torque 3 92 to 5 88 N m 0 4 to 0 6 kgf m 3 Connect cable 4 at the positive terminal end 4 Connect connection cable 5 from the terminal 5 Connect cable 3 to the negative terminal end groun...

Page 271: ...plosion Connect the positive charger clip of the charger to the positive terminal of the battery then connect the negative charger clip of the charger to the negative terminal of the battery Be sure to attach the clips securely Set the charging current to 1 10 of the value of the rated battery capacity when carrying out rapid charging set it to less than the rated battery If the charger current is...

Page 272: ...or contact the chassis CAUTION The size of the booster cable and clip should be suitable for the battery size The battery of the normal machine must be the same capacity as that of the engine to be started The starting system for this machine uses 24 V For the normal machine also use a 24 V battery Check the cables and clips for damage or corrosion Connect the clips firmly Check that the lock leve...

Page 273: ...try again after 2 minutes or so NOTES For details of the engine starting see operation 3 2 Starting Engine BOOSTER CABLE DISCONNECTION After the engine has started disconnect the booster cables in the reverse of the order in which they were connected 1 Remove one clip of booster cable B from the upper structure frame E of the problem machine 2 Remove the clip of booster cable B from the negative t...

Page 274: ...ty relay Charge Replace Starter motor turns engine sluggishly Insufficient battery charge Defective starter motor Charge Replace Starter motor disengages before engine starts Defective wiring defective ring gear and pinion Insufficient battery charge Check repair Charge Starter motor turns but engine does not start Defective engine controller power supply circuit Defective relay Defective connecto...

Page 275: ...the specified capacity see Check Before Starting Pump generates abnormal noise sucking in air Clogged element in hydraulic oil tank strainer lack of oil Clean see Maintenance for 5000 Hours Excessive rise in hydraulic oil temperature Loose fan belt Dirty oil cooler Lack of hydraulic oil Check fan belt tension replace Clean see Every 500 Hours Maintenance Add oil to specified level see Check Before...

Page 276: ...ng system Clogging radiator fins or damaged fins Defective thermostat Loose radiator filler cap high altitude operations Defective monitor Add coolant to specified level see Check Before Starting Check repair Adjust fan belt tension see Every 250 Hours Maintenance Change coolant flush inside of cooling system see Irregular Maintenance Clean or repair see Every 500 Hours Maintenance Replace thermos...

Page 277: ...ger Combustion noise occasionally make breathing sound Defective nozzle Replace nozzle Abnormal noise generated combustion or mechanical Low grade fuel being used Overheating Damage inside muffler Excessive valve clearance Change to specified fuel See Engine water temperature gauge indicator is in red range above Replace muffler Adjust valve clearance Engine stops while in work Clogged pre filter ...

Page 278: ...r Engine controller drive system circuit error engine stopped Have inspection carried out immediately E11 Engine controller system error out put reduced to protect engine Operate machine to a safety posture and have inspection carried out immediately E14 Abnormality in throttle system Operate machine to a safety posture and have inspection carried out immediately E15 Engine sensor coolant temperat...

Page 279: ...place moment limiter trans ducer Defective moment limiter emer gency stop cancel switch Check replace emergency stop cancel switch Defective solenoid valve spool Repair replace solenoid valve Crane operations does not stop even when overloaded Short circuit in the emergency power supply circuit Check replace solenoid valve wiring Defective wiring between the moment limiter transducer and solenoid ...

Page 280: ...g operation not activated even when not over hoisted Problem Main causes Remedy Defective over hoist detector Check replace over hoist detector Breakage of over hoist detector wiring or entanglement of the wiring Check repair or replace over hoist detector wiring Loss of over hoist detector weight Check replace over hoist detector weight Boom extending or hook hoisting operation not activated even...

Page 281: ...TY CRITICAL PARTS 4 8 5 CONSUMABLES 4 9 6 OTHER COMPONENTS 4 10 7 USE OF FUEL COOLANT AND LUBRICANT 4 11 8 TIGHTENING TORQUE SPECIFICATIONS 4 13 9 INSPECTION AND MAINTENANCE LIST 4 14 10 MAINTENANCE PROCEDURES 4 17 11 BLEEDING AIR FROM HYDRAULIC SYSTEM 4 76 12 RELEASING PRESURE METHOD IN HYDRAULIC CIRCUIT 4 80 4 1 ...

Page 282: ...ent temperature USE CLEAN OIL AND GREASE Always use clean oil grease and containers to keep out impurities USE CLEAN WINDOW WASHER FLUID Always use automobile window washer fluid and be careful not to let any dirt get into it KEEP THE MACHINE CLEAN Keep the machine clean to facilitate detection of a malfunction In particular keep grease nipples breather and oil level gauge oil access cap clean to ...

Page 283: ...ot loose cracked or suffering from abrasion Loosen the tension of the crawler tread to a greater degree than usual CAUTIONS REGARDING MACHINE WASHING Do not direct a jet of steam at electrical parts or connectors Keep the operation panel dry In particular the underside of the operator s seat and the area around the battery must be protected from water Wash the machine with a clean cloth to rinse o...

Page 284: ...d exhaust gas characteristics the engine mounted on this machine uses a high pressure fuel injection device This device requires high precision parts and high level lubricating properties If therefore low viscosity fuel with low lubricating capabilities is used its durability may be considerably degraded The fuel pump is a precision item of equipment that becomes inoperative if fuel containing moi...

Page 285: ...ways use genuine Maeda filters HANDLING COOLANT River water contains a large amount of calcium and impurities Use of river water will result in water sludge accumulating in the engine and radiator which will cause a heat exchange error and lead to overheating Do not use any impure water When using antifreeze be sure to follow the precautions stated in the operating manual Keep antifreeze away from...

Page 286: ...vel Internal pressure may still be exerted despite the temperature drop When removing the plugs screws and hose joints stand aside and loosen them gradually while releasing internal pressure Be sure to release the internal pressure by releasing air from the hydraulic tank before carrying out inspection and maintenance tasks of the hydraulic circuit Inspection and maintenance tasks include checking...

Page 287: ...ch wire rope end and wire clip for damage 4 Replace the wire rope promptly if it is damaged 5 Check the hydraulic oil hose for oil leaks and friction flaws on the surface Replace the hose if any surface flaws are detected 6 Check the structure including the boom for cracks and deformations 7 Check that all mounting bolts and joints are tight and secure 8 Check whether the crane operates and stops ...

Page 288: ...g checks for the hydraulic oil hoses that are not due for periodic replacement If any abnormalities are discovered tighten loose clamps and replace defective hoses as required When replacing hoses always replace O rings and gaskets at the same time When replacing safety critical parts contact us or our sales service agency SAFETY CRITICAL PARTS LIST No Safety critical parts for periodic replacemen...

Page 289: ...return filter Every 1000 hrs Hydraulic line filter Every 1000 hrs Main fuel filter Every 1000 hrs Air cleaner element As required Cylinder gasket Every 3 yrs Boom slide plate Every 3 yrs Winch wire rope As required or every 3 years Boom extending wire rope As required or every 3 years Boom retracting wire rope As required or every 3 years Air conditioner internal filter every 1 years Air condition...

Page 290: ...cription Quant ity Description Quant ity 1 Glass 1 12 Rear view mirror 1 2 Glass 1 13 Rear view mirror 1 3 Clear plate 1 14 Rear view mirror 1 4 Glass 1 Fuse 30A 2 5 Glass 1 Fuse 20A 3 6 Glass 1 Fuse 15A 1 7 Glass 1 Fuse 10A 9 8 Glass 1 15 Fuse 5A 5 Working lamp 1 Fusible link 50A 1 9 Bulb 70W 1 Fusible link 120A 1 Working lamp 1 Fusible link 45A 2 10 Bulb 70W 1 16 Interior light 1 17 Fan belt 1 1...

Page 291: ...engine at temperatures below 0 degrees C be sure to use the recommended multi grade oil even if the ambient temperature may rise during the course of the day 7 1 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURES Use the oil selectively according to the ambient temperature shown in the chart below Ambient Temperature degrees C Reservoir Fluid type Min Max Recommended Fluids 30 30...

Page 292: ... engine oil Be sure to use the recommended oils Note 2 Supercoolant AF NAC 1 Supercoolant has the important function of acting as an anticorrosion liquid as well as antifreeze Even in the areas where freezing is not an issue the use of antifreeze coolant is essential Maeda machines are supplied with Supercoolant AF NAC Supercoolant AF NAC has excellent anticorrosion antifreeze and cooling properti...

Page 293: ...4 0 2 8 3 5 10 17 66 0 6 70 59 0 74 0 6 0 7 5 12 19 113 11 5 98 0 123 10 0 12 5 14 22 172 17 5 153 190 15 5 19 5 16 24 260 26 5 235 285 23 5 29 5 18 27 360 37 0 320 400 33 0 41 0 20 30 510 52 3 455 565 46 5 58 0 22 32 688 70 3 610 765 62 5 78 0 24 36 883 90 0 785 980 80 0 100 27 41 1295 132 5 1150 1440 118 147 30 46 1720 175 0 1520 1910 155 195 33 50 2210 225 0 1960 2450 200 250 36 55 2750 280 0 2...

Page 294: ...UELING FUEL LEVEL IN FUEL TANK 3 113 CHECKING REFILLING OIL LEVEL IN HYDRAULIC TANK 3 114 CHECKING DUST INDICATOR 3 116 CHECKING FOR WATER SEDIMENT IN WATER SEPARATOR DRAIN WATER 3 117 DRAIN WATER AND SEDIMENT FROM FUEL TANK 3 118 CHECKING ELECTRICAL WIRING 3 119 CHECKING WORKING LAMP 3 119 CHECKING FUNCTION OF HORN 3 119 ADJUSTING OPERATOR S SEAT 3 120 ADJUSTING MIRRORS 3 121 OPERATIONS BEFORE ST...

Page 295: ... 47 CHECKING ADJUSTING COOLING FAN BELT TENSION 4 48 CHECKING ADJUSTING AIR COMPRESSOR BELT TENSION 4 50 MAINTENANCE EVERY 500 HOURS REPLACEMENT OF ENGINE LUBRICATING OIL AND OIL FILTER CARTRIDGE 4 51 REPLACEMENT FUEL PRE FILTER CARTRIDGE 4 53 CHECKING SWING PINION GREASE LEVEL ADDING GREASE 4 55 GREASING SWING CIRCLE Slew ring bearing 4 55 CLEANING CHECKING RADIATOR FINS OIL COOLER FINS FUEL COOL...

Page 296: ...ARTER MOTOR 4 71 CHECKING ADJUSTING ENGINE VALVE CLEARANCE 4 71 MAINTENANCE EVERY 4000 HOURS CHECKING WATER PUMP 4 72 REPLACEMENT ACCUMULATOR FOR CONTROL CIRCUIT 4 72 MAINTENANCE EVERY 5000 HOURS REPLACING HYDRAULIC TANK OIL AND CLEANING STRAINER 4 73 4 16 ...

Page 297: ...SE For the maintenance procedure see maintenance every 1000 hours 10 2 CHECKING BEFORE OPERATION Inspections specified in this section are required to be completed prior to starting an engine at the start of the day For the items used in the Checking Before Operation see 9 Inspection and Maintenance List For the applicable parts of each of the inspection items listed in the Checking before Operati...

Page 298: ...of the wires in one twist of the wire rope or 5 or more when such nipped wires are in one single strand 2 20 or more of the wires in five twists of the wire rope 2 The diameter of the wire rope is worn for 7 or more of the nominal diameter NOTES Replace a 10 mm diameter wire rope if it is 9 4 mm in diameter Replace a 8 mm diameter wire rope if it is 7 5 mm in diameter 3 The wire rope corroded as b...

Page 299: ...ng procedure to remove the wire rope 1 Station the machine on a level and solid ground and set it to a posture with minimum boom length and 20 degrees of the angle 2 At the posture as 1 above un wind the hook block until it nearly touches the ground 3 Operate the right work equipment control lever in the BOOM LOWER position push it toward outside to lower the hook block on the ground 4 Remove the ...

Page 300: ...e the right work equipment control lever in the HOOK LOWER position push it toward front to wind off the wire rope 5 from the winch drum 9 9 With the wire rope 5 wound off of the winch drum 9 remove the end of the wire rope 5 from the winch drum 9 by following the procedure provided below 1 Bring a 6 to 10 mm round bar A into contact with the rope wedge 10 2 Remove the rope wedge 10 lightly tappin...

Page 301: ...st detector load sheave 11 at the boom end wire guide 12 of No 3 4 and 4 boom roller sheave 13 sheave 14 inside derricking cylinder bracket and slide sheave 14 2 Draw the wire rope 5 through the attachment hole of the winch drum 9 Secure the wire rope 5 to the winch drum 9 following the procedure provided below 1 Draw the wire rope 5 through the winch drum 9 with the rope loose 2 The rope wedge 10...

Page 302: ...6 Secure the end of the wire rope 5 to the wire socket 3 following the procedure provided below 1 Draw the wire rope 5 through the wire socket 3 as shown at right 2 With the rope wedge 6 in position a yank at the wire rope 5 in the direction indicated by the arrow 7 Install the rope clip 4 to the wire rope 5 8 Secure the wire socket 3 to the boom with the wire socket pin 2 and tighten the wire soc...

Page 303: ...NDING position pull it forward to raise the hook block NOTES Winch operation is allowed only after the hook block is raised 10 With the boom extended and raised fully 11 With the wire rope 5 held under tension place the right work equipment control lever in the HOOK RAISING position pull it toward you to wind up the wire rope 5 in the winch drum 9 4 23 ...

Page 304: ...t appears in the boom extending wire rope 1 Set boom to level position and check if boom extending wire rope is slack in the centre by more than 30mm during boom retracting operation If wire rope is slack by more than 30mm refer to the section for wire rope adjusting 2 Set boom to level and fully retracted position 3 Measure and check if clearance between boom 3 and boom 4 Clearance a in the drawi...

Page 305: ...asure the clearance a and clearance b and judge as follows If the clearance a is less than 5mm wire rope adjustment is not needed If the clearance a is more than 5mm adjust wire rope referring to item 4 Adjusting boom 4 retracting wire rope 6 If the clearance a is 0mm adjust wire rope referring to item 5 Adjusting extending wire rope 7 for boom 4 4 Adjusting retracting wire rope 6 for boom 4 1 Loo...

Page 306: ... 0mm carry out adjustment in item 8 Adjusting boom 5 extending wire rope 9 7 Adjusting retracting wire rope 8 for boom 5 1 Loosen lock nut 14 and tighten adjusting nut 15 to the direction retracting wire rope 8 tensions until the clearance b becomes less than 5mm evenly on both left and right side 2 Follow procedure 1 2 and 3 again and if the clearance b still exceeds 5mm adjust it again 8 Adjusti...

Page 307: ...n the air cleaner element CAUTION Do not clean the air cleaner element before the red piston appears in the transparent portion of the dust indicator 1 If the air cleaner element is cleaned frequently before the red piston appears the air cleaner will not provide the originally intended level of performance which will reduce the level of cleaning efficiency CLEANING OUTER ELEMENT 1 Set the cleaned...

Page 308: ...ng the cleaned outer element even through it has not been cleaned 6 times Remove one seal from the element whenever the element has been cleaned 6 After cleaning if any small holes or thinner parts are found on the element when it is checked by shining a light through it replace the element CAUTION When cleaning the element do not hit it or beat it against something Do not use an element whose fol...

Page 309: ...the inside of the air cleaner body and the cover 3 CAUTION When cleaning cover 3 do not remove evacuator valve 6 5 Remove inner element 5 and then install a new inner element immediately When installing the cover 3 check O ring 7 and replace it if there are any scratches or dmage 6 Set new outer element 4 and install cover 3 by matching marks 8 with main body and secure by clip 2 7 Replace the sea...

Page 310: ...8 Press the button of dust indicator to return the red piston to its original position 4 30 ...

Page 311: ...nts of ASTM D3306 03 Stop the machine on level ground then clean or replace the coolant The coolant has the important function of preventing corrosion as well as preventing freezing Even in the area where freezing is not an issue the use of antifreeze coolant is essential Maeda machine are supplied with Supercoolant AF NAC Supercoolant AF NAC has excellent anticorrosion antifreeze and cooling prop...

Page 312: ... of antifreeze is to be controlled by the concentration meter Prepare a container with a capacity of at least 11 liter to catch the coolant Have a water filling hose available 1 Stop the machine on level ground and stop the engine 2 Open engine hood and surely lock to hold the door with hood support bar 3 Open maintenance door on right rear side and set rod into hitch to hold the door open 4 Check...

Page 313: ...pe onto drain plug 3 then tighten it 12 Fill with super coolant and tap water through the water filler up to the bottom of the filler For details of the mix ratio for super coolant and water see chart MIXING RATIO OF WATER AND ANTIFREEZE 13 To bleed the air from the cooling system run the engine at low idle for 5 minutes and for a further 5 minutes at high idle When doing this leave the radiator c...

Page 314: ... water e g commercially available battery replenishing fluid may become frozen overnight refill it next day before starting the day s work Inspect the battery electrolyte level at least once a month following the standard given below WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY 1 Take off stowage rope from rope holder 2 Hold handle of battery inspection cover 1 and lift the cover 1 to open...

Page 315: ...olyte Neutralize the removed fluid with sodium bicarbonate then flush it away with a large amount of water Or contact us our sales service agency or the battery manufacturer WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use an indicator to check the electrolyte level follow the instructions given 4 35 ...

Page 316: ...ating surface CHECKING ADJUSTING TRACK TENSION The wearing speed of the pins and bushings on the undercarriage varies depending on the working conditions and type of soil so you must check the track tension frequently to maintain the standard tension Stop the machine on firm level ground when carrying out the inspection and maintenance tasks INSPECTION 1 Run the engine at a low idle move the machi...

Page 317: ...just it according using the following procedures INCREASING TRACK TENSION Prepare a grease pump 1 Pump in grease through grease plug 2 with a grease pump 2 To check that the track tension is correct run the engine at a low idle move the machine forward by the ground contact length and then stop the machine 3 Check the track tension again If the tension is not appropriate adjust it again CAUTION It...

Page 318: ...ack tension again and if the tension is not correct adjust it again CHECKING WINDOW WASHER FLUID LEVEL ADDING FLUID If there is air in the window washer fluid check the level of the fluid in window washer tank 1 Add automobile window washer fluid if necessary NOTES When adding fluid be careful not to let any dust get in MIXTURE RATIO OF PURE WASHER FLUID AND WATER The proportion differs according ...

Page 319: ...orless transparent No refrigerant NOTES When there are bubbles the refrigerant gas level is low so contact us or our sales service agency to have refrigerant added If the air conditioner is run with the refrigerant gas level low it will cause damage to the compressor INSPECTION DURING OFF SEASON Even during the off season operate the air conditioner for 3 to 5 minutes once a month to maintain the ...

Page 320: ...R RAIL 1 Open and close the door and use a brush to remove any dirt from rail 1 2 Use a cloth to wipe off any dirt from rail 1 GREASING DOOR RAIL AND ROLLER CAUTION Do not use high viscosity oil for the lubricant Use grease only 1 Spray rail 1 and roller 2 thoroughly with lubricant 2 After spraying with lubricant slide the door and check that the door opens and closes smoothly If the movement is n...

Page 321: ...by fusing Do not cause an impact by hitting or rolling it Before discarding it enclosed gas must be released Request Maeda service agency for releasing the gas Gas spring is located in left console one location Please contact us or our sales service agency for inspection repair or replacement if any condition as below applies When pulling up lock lever it does not come up with light power Lock lev...

Page 322: ...grease 6 Greasing of the boom slide plate upper 8 places 7 Greasing of the boom slide plate lower 8 places Molybdenum grease 8 Greasing of both sides and bottom of a boom Each boom Grease for boom 9 Greasing of boom extending wire rope Greasing of the winch wire rope 5 places Rope oil 10 Greasing of the hook block 1 piece Lithium grease 1 With the use of the grease gun grease the greasing points N...

Page 323: ...4 43 ...

Page 324: ...d may cause serious burns Wait for the temperature to go down before starting the operation CAUTION For details of using oil specified see Maintenance 7 1 Use of Fuel Coolant and Lubricants According to Ambient Temperature After checking or refilling insert the dipstick securely 1 Set boom to fully retracted and fully derricked position 2 Shift lock lever to lock L position and stop engine 3 Loose...

Page 325: ...tick G add oil through filler port cap F NOTES The oil must be filled from the filler cap F up to midway between the H and L marks of the dipstick G 8 If the oil level exceeds the H mark on the level gauge G exercise a practice below 1 Swing the upper structure so that drain plug P comes between the right and left tracks 2 Remove drain plug P to drain the excess oil 9 After checking oil level or a...

Page 326: ...t Temperature Use seal tape etc at the thread of the filler plug to stop the oil leak and securely tighten the plug after refilling with the oil Prepare a container to catch drain oil Prepare a hexagon wrench 1 Set plug F and plug P vertical to the ground with plug F at the top 2 Place a container for receiving oil under drain plug P 3 Using a hexagon wrench remove plug G If the oil is filled near...

Page 327: ...e thread of the filler plug to stop the oil leak and securely tighten the plug after refilling with the oil Prepare a container to catch drain oil Prepare a hexagon wrench 1 Stop the machine on level and solid ground and raise the boom to 80 degrees 2 Shift lock lever to lock L position and stop engine 3 Place a container for receiving oil under plug G 4 Using a hexagon wrench and remove plug G Wh...

Page 328: ... CHECKING 1 Open engine hood 2 Loosen 2 bolts and remove guard 1 3 Deflection A should be 9 to 13 mm when the belt is pressed with the thumb with a force of approx 58 8 N 6 kg at a point midway between the alternator pulley and crank pulley 4 48 ...

Page 329: ...nsion is 9 to 13 mm approx 58 8 N 6 kg When doing this do not touch double nut 6 7 Tighten mounting bolt 3 and lock bolt 4 8 Tighten nut 6 CAUTION Inspect the followings as well when you inspect the tension of the fan belt Check each pulley for damage wear of the V groove and wear of the V belt In particular be sure to check that the V belt is not touching the bottom of the V groove If the belt is...

Page 330: ...are loosened bracket 5 moves with the bolt 7 securing position as a fulcrum 3 Deflection A should be 12 to 15 mm when the belt is pressed with the thumb with a force of approx 58 8 N 6 kg at a point midway between the compressor pulley 2 and crank pulley 3 4 Tighthen bolt 6 and 7 CAUTION Inspect the followings as well when you inspect the tension of the air compressor belt Check each pulley for da...

Page 331: ...nt The complete draining of oil is not possible if the engine becomes completely cold Oil draining is allowed when the engine is cold to touch Keep impurities out of the filler cap when replenishing oil Oil pan refill amount 11 liters Prepare a container to catch drain oil 15 liters or more Prepare a filter wrench 1 Then set the container under drain valve P on the left side of the machine to catc...

Page 332: ...ter it will cause leakage of oil 7 When installing tighten until the packing surface contacts the filter holder then tighten a further 1 2 turn 8 After replacing the filter cartridge add oil through oil filler F until the oil level is between H and L marks on the dipstick G 9 Run the engine at idle for a short time then stop the engine and check that the oil level is between the H and L marks on t...

Page 333: ...ction system Always avoid using substitute parts When carrying out inspection or maintenance of the fuel system pay more attention than normal to the entry of dirt If dirt is stuck to any part use fuel to wash it off completely Prepare a container to catch drain fuel Prepare a filter wrench 1 Open engine hood and surely lock to hold the door with hood support bar 2 Set valve 1 at the side of the f...

Page 334: ... fuel will also leak from the packing so always tighten the correct amount When tightening with a filter wrench be extremely careful not to dent or damage the filter 11 Check that the drain valve 2 is tightened securely 12 Set valve 1 at the side of the fuel pre filter cartridge to the open position O 13 After completing the replacement of filter cartridge 4 bleed air PROCEDURE FOF BLEEDING AIR Bl...

Page 335: ...rtion where the pinion passes is at least 4 mm Add more grease if necessary 5 Check if the grease is milky white If it is milky white it is necessary to change the grease Please contact us or our sales service agency Total amount of grease 5 5 liters 5 0 kg 6 Set rubber cap 3 7 Set cover 1 and floor mat GREASING SWING CIRCLE Slew ring bearing 1 Using a grease gun pump in grease through the grease ...

Page 336: ... wing screws 1 and remove net 2 4 Clean net 2 5 Check the front and rear surfaces of oil cooler fins 3 radiator fins 4 after cooler fins 5 air conditioner condenser fins 6 and fuel cooler fins 7 If there is any mud dirt or leaves stuck to the fins blow the dirt off with compressed air NOTES Steam or water may be used instead of compressed air However when carrying out powerful steam cleaning highp...

Page 337: ...an extremely dusty jobsite reduce the maintenance interval and clean the filter more frequently When washing the floor be careful not to get water on the air conditioner system CLEANING RECIRCULATED AIR FILTER 1 Open cover 1 at the front bottom left of the operator s seat 2 Take out internal filter 2 3 Clean internal filter 2 with compressed air If there is oil stuck to the filter 2 or it is extre...

Page 338: ...g it again NOTES Replace the filter with a new part every year If the clogging of the filter cannot be removed by blowing with air or washing in water replace the filter immediately 4 After cleaning return filter 2 to its original place 5 Remove support lever 3 and close the cover 1 When doing this lock it with the starter key After locking it do not forget to remove the starter key NOTES The FRES...

Page 339: ...oving the oil filter cap turn it slowly to release the internal pressure then remove it 1 Loosen 5 bolts Remove cover 1 at the top of the hydraulic tank 2 Loosen bolt 2 remove upper plate 3 on oil filler F and take off cap of oil filler F to relieve inner pressure 3 Replace element 4 inside the cap 4 Set cap to oil filler F 5 Set plate 3 to the center of the cap and fix with bolt 2 6 Set cover 1 a...

Page 340: ...t and Lubricants According to Ambient Temperature After replacing oil fully insert dipstick securely Refill capacity 2 0 liters Prepare a container to catch drain oil 1 Swing the upper structure so that drain plug P is between the left and right tracks 2 Set a container under drain plug P at the bottom of the machine 3 Remove drain plug P at the bottom of the machine drain the oil 4 After draining...

Page 341: ...he oil level should be between the H and L marks on oil level gauge G 12 If the oil level is below L on oil level gauge G replenish the engine oil through the gauge insertion port F NOTES The oil must be filled up to midway between the H and L marks of the dipstick G 13 If the oil is above the H mark drain the excess oil from drain plug P then check the oil level again 14 After adding insert dipst...

Page 342: ...sition L and stop the engine 3 Loosen 4 bolts and remove cover 1 4 Inject grease using grease pump through the grease fittings indicated by arrows Grease amount 100g NOTES Necessary amount of grease can be injected by about 100 times of pumping by grease pump The old grease pushed out drops on grease bath of swing pinion but this is no problem 4 62 ...

Page 343: ...emperature Use seal tape etc at the thread of the filler plug to stop the oil leak and securely tighten the plug after refilling with the oil Refill capacity each 1 1 liters Prepare a container to catch drain oil Prepare a hexagon wrench 1 Move the machine forward and reverse set so that plug F is at the top with plug F and plug P perpendicular to the ground 2 Place a container for receiving oil u...

Page 344: ...CAUTION For the oil used see Inspection and Maintenance 7 1 Use of Fuel Coolant and Lubricants According to Ambient Temperatures After refilling the oil use the seal tape to prevent leakage of oil from the threaded portion of the plug then securely tighten the plug Refill capacity 1 8 liters Prepare a container to catch drain oil Prepare a hexagon wrench 1 Stop the machine on a level and solid gro...

Page 345: ...ove plugs F G and P then drain oil 5 After draining oil install drain plug P securely 6 Add the replacement amount of oil through the hole of plug F 7 After the oil flows out of the hole for plug G install plugs G and F securely 4 65 ...

Page 346: ...tails of using oil specified see Maintenance 7 1 Use of Fuel Coolant and Lubricants According to Ambient Temperature The engine must be at halt until piping and hydraulic equipment is filled with oil after replacement of the hydraulic oil filter Prepare a container to catch drain oil Prepare a filter wrench 1 Stow hook block and set the machine into traveling posture as illustrated in the right di...

Page 347: ...nd this will lead to leakage of fuel If the filter cartridge is too loose fuel will also leak from the packing so always tighten the correct amount When tightening with filter wrench be careful not to damage or dent filter 8 Move filler cap F and plate 3 to the center of the cap and fix with bolt 2 9 Set cover 1 above the hydraulic oil tank 10 To remove air operate in low idling for 10 minutes aft...

Page 348: ...d set the machine into traveling posture as illustrated in the right diagram 2 Open engine hood and surely lock to hold the door with hood support bar 3 Set container to catch drained oil under the filter element 4 Turn filter case 1 to left and remove then remove element 2 and O ring 3 from filter holder 5 Clean filter holder 4 and filter case 1 and apply clean hydraulic oil to packing of new ele...

Page 349: ...consists of more precise parts than the conventional injection pump and nozzle If any part other than a genuine Maeda filter cartridge is used dust or dirt may get in and cause problems with the injection system Always avoid using substitute parts When carrying out inspection or maintenance of the fuel system pay more attention than normal to the entry of dirt If dirt is stuck to any part use fuel...

Page 350: ...ull it out and then pump it in and out until the movement becomes heavy NOTES It is not necessary to remove the plug at the top of the fuel pre filter and fuel main filter After the engine runs out of fuel use the same procedure to operate feed pump 4 and bleed the air 3 After finishing the bleeding of air push in the knob of feed pump 4 and tighten it 4 After replacing the filter cartridge start ...

Page 351: ...brushes may be worn or the bearing may have run out of grease contact us or our sales service agency for inspection and repairs If the engine is started frequently have this inspection carried out every 1000 hours CHECKING ADJUSTING ENGINE VALVE CLEARANCE Special tools are needed for inspection and maintenance please contact us or our sales service agency 4 71 ...

Page 352: ...circuit cannot be completely removed When removing the hydraulic equipment do not stand in the direction that the oil spurts out when carrying out the operation In addition loosen the bolts slowly when carrying out the operation Do not disassemble the accumulator Do not bring it near flame or dispose of it in fire Do not make holes in it or weld it Do not hit it roll it or subject it to any impact...

Page 353: ... sure to put the machine in the Travelling posture when checking the oil level Checking the oil level in the working posture will cause overfilling since the oil in the cylinders has not returned to the tank For details of Travelling posture see Operation 3 7 Machine Travelling Posture The engine must be at halt until piping and hydraulic equipment is filled with oil after replacement of the hydra...

Page 354: ...g torque 58 8 to 78 4 Nm 6 to 8 kgfm 10 Remove bolt 4 and cover 5 At this time spring 6 may push cover to jump so press down cover during removing bolt 11 Hold the top of rod 7 and pull up to remove spring 6 and strainer 8 Remove any dirt stuck to strainer 8 and then wash it in flushing oil If strainer 8 is damaged replace it with a new part 12 When installing insert strainer 8 into protruding par...

Page 355: ...hown in the diagram on the right and then set the oil filler cap to pressurize inside tank CAUTION Unless hydraulic tank is not pressurized pump intakes air and causes bad influence to the equipment 16 Move plate 3 to the center of cap and fix with bolt 2 17 Set cover 1 above the hydraulic oil tank 18 After replacing cleaning hydraulic oil filter element and strainer relieve air in circuit Refer t...

Page 356: ...ation tighten the air bleed plug 1 AIR RELIEF BETWEEN PUMP AND HYDRAULIC OIL TANK CAUTION If you set the engine idling to high speed without relieving the air between the pump and the hydraulic oil tank the pump may heat up abnormally and may suffer damage early 1 Start the engine by referring to the Operations 3 2 Starting the engine section then keep the engine idling to the middle speed 1650 rp...

Page 357: ...ure at least 2 times uniformly to the left and right BLEEDING AIR FROM TRAVELLING MOTOR CAUTION Only when oil inside Travelling motor case has been drained 1 Start the engine and then run the engine at low idle 2 Remove hose 5 from port D then when the oil has flowed out tighten it again 3 Stop the engine and then raise the undercarriage For details see following procedure 4 Start the engine again...

Page 358: ...en move Any procedure to lift up the crane other than below is strictly prohibited Otherwise the machine may lose balance Prepare a rectangular lumber 450mm X 450mm to put under the track frame 1 Configure the machine to the Travelling posture as shown the figure in the right 2 Swing the upper structure 90 degrees 3 Attach the sling wire rope A below the boom and lift the machine up slowly NOTES F...

Page 359: ...NEUTRAL position 2 Loosen the bleeder plug 1 for the mechanical brake for 3 to 4 turns 3 Slowly wind up stop and un wind the hook block without any load 4 When the hydraulic oil leaks from segment of the bleeder plug 1 for the mechanical brake stop the winch operation and tighten the bleeder plug 1 securely Tightening torque 12 3 Nm 1 25 kgfm BLEEDING FROM THE COUNTER BALANCE VALVE 1 Lower the hoo...

Page 360: ...ne When the engine stops the pressure in the accumulator will gradually go down so the pressure can only be release immediately after the engine is stopped 1 Stop the machine at leveled location 2 Lower the blade to the ground 3 Turn the starter switch to the OFF position and stop the engine 4 Turn the starter switch to the ON position 5 Set the lock lever to the FREE position F then operate each ...

Page 361: ...SPECIFICATIONS 1 SPECIFICATION LIST 5 2 2 SPECIFICATION DIMENSIONAL DRAWING 5 4 3 RATED TOTAL LOAD CHART 5 5 4 WORKING RADIUS AND LIFTING HEIGHT 5 8 5 1 ...

Page 362: ... 0 0 φ10 72 9KN 115m Method 2 sequential telescoping double acting hydraulic cylinders 2 wire rope telescoping device Boom type Pentagonal sectioned hydraulic automatic telescoping boom 5 sections sections 3 4 and 5 simultaneous Boom length 4 63m 7 38m 10 13m 12 88m 15 63m Boom telescopin g system Boom telescoping stroke time 11 0m 25 0sec Method Direct push type hydraulic double acting cylinder B...

Page 363: ...1 0kW 1 950min 1 55PS 1950rpm Engine Fuel tank capacity Light oil 140liters Safety device Overwind protections moment limiter with working envelope restriction wire rope latch hydraulic safety valve alarm buzzer machine body inclination alarm working status lamp level control lock lever travel lock bar side mirror emergency stop switch and crane blade interlock device 5 3 ...

Page 364: ...2 SPECIFICATION DIMENSIONAL DRAWING 5 4 ...

Page 365: ...1340 770 1280 1200 5 50 1180 690 1170 680 1130 1090 6 00 1000 590 1030 590 1010 990 6 27 910 540 950 550 940 940 6 50 890 510 900 900 7 00 780 440 800 820 7 50 670 380 710 750 8 00 580 320 630 680 8 50 490 270 560 610 9 00 410 230 500 560 9 02 410 230 500 560 9 50 440 500 10 00 390 450 10 50 340 400 11 00 300 360 11 50 260 320 11 77 260 300 12 00 280 12 50 240 13 00 210 13 50 200 14 00 200 14 52 2...

Page 366: ...0 1200 5 50 1180 690 1170 680 1130 1090 6 00 1000 590 1030 590 1010 990 6 27 910 540 950 550 940 940 6 50 890 510 900 900 7 00 780 440 800 820 7 50 670 380 710 750 8 00 580 320 630 680 8 50 490 270 560 610 9 00 410 230 500 560 9 02 410 230 500 560 9 50 440 500 10 00 390 450 10 50 340 400 11 00 300 360 11 50 260 320 11 77 260 300 12 00 280 12 50 240 13 00 210 13 50 200 14 00 200 14 52 200 Boom leng...

Page 367: ... 1200 5 50 1180 690 1170 680 1130 1090 6 00 1000 590 1030 590 1010 990 6 27 910 540 950 550 940 940 6 50 890 510 900 900 7 00 780 440 800 820 7 50 670 380 710 750 8 00 580 320 630 680 8 50 490 270 560 610 9 00 410 230 500 560 9 02 410 230 500 560 9 50 440 500 10 00 390 450 10 50 340 400 11 00 300 360 11 50 260 320 11 77 260 300 12 00 280 12 50 240 13 00 210 13 50 200 14 00 200 14 52 200 Boom lengt...

Page 368: ...4 WORKING RADIUS AND LIFTING HEIGHT WORKING RADIUS AND LIFTING HEIGHT AT WIRE ROPE 4 FALLS 5 8 ...

Page 369: ...WORKING RADIUS AND LIFTING HEIGHT AT WIRE ROPE 2 FALLS 5 9 ...

Page 370: ...WORKING RADIUS AND LIFTING HEIGHT AT WIRE ROPE 1 FALLS 5 10 ...

Page 371: ...CATION 6 4 3 WORKING RANGE CHART 6 5 4 TOTAL RATED LOAD CHART 6 6 5 FLY JIB EACH SECTION 6 7 6 FLY JIB INSTALLATION AND STOWAGE 6 8 7 HANDLING MOMENT LIMITER 6 20 8 OPERATIONS 6 25 9 TRANSPORTATIONS 6 25 10 INSPECTION AND MAINTENANCE 6 26 11 SPECIFICATIONS 6 27 6 1 ...

Page 372: ...not a serious hazard may result including Fly jib damage or the machine tipping over The Fly jib is stowed to the side of the Main boom and fixed to it with two position pins When installing or stowing the fly jib always ensure either position pin is inserted in the correct position and secured by their linchpins Otherwise if any of the pins drop out the Fly jib will become detached from the main ...

Page 373: ... degrees in addition to that the Main boom is extended for 50cm or longer the Moment limiter will issue an over load warning with an intermittent warning buzzer and hook raising boom extending and boom lowering functions are automatically interrupted However where the boom extension is less than 50cm the Moment limiter will not issue an over load warning While the boom angle is in a range of less ...

Page 374: ...dard model Keep these safety labels clean and legible at all times When a safety label is degraded missing or illegible replace with a new label In addition to the safety labels shown below some other labels are required used Control them in the same manner 2 1 SAFETY LABEL LOCATION AT FLY JIB 1 Over hoist Alarm Wiring Instruction 556 3428500 6 4 ...

Page 375: ...3 WORKING RANGE CHART 6 5 ...

Page 376: ... CAUTION The total rated load is a load including the mass of a hook block 20kg Total rated load kg Boom angle deg Jib length 1 section 3 0m Jib length 2 section 4 7m 80 430 430 70 430 430 65 330 330 60 230 230 55 130 130 6 6 ...

Page 377: ...3 Hook stowing bracket 3 No 2 Fly jib 14 Position pin 4 Wire guide A 15 Position pin 5 Wire guide B 16 Harness connection part Fly jib side 6 Sheave 17 Harness connection part Main boom side 7 Sheave 18 Fly jib bracket A 8 Wire rope 19 Fly jib bracket B 9 Sheave 10 Weight 6 7 ...

Page 378: ...on pins are inserted in the correct positions and secured by linchpins as well Otherwise if any of the pins drops out the Fly jib will drop which may cause a serious hazard Whenever the Fly jib is installed it is essential to re connect the over hoist detector harness from the Main boom detector to the Fly jib detector Always ensure the over hoist detector of the Fly jib is working correctly befor...

Page 379: ...ition from the right side as shown below 1 Pull the linchpin 20 out from the position pin 14 in the Fly jib bracket B 19 to pull out the position pin 14 NOTES The removed position pin 14 will be required for the later operation of attaching the Fly jib to the right side of the Main boom tip 6 9 ...

Page 380: ...hole then secure it with the linchpin 20 NOTES If it is difficult to insert position pin 14 then move D portion of No 1 Fly jib up down or side to side to align pin holes Do not remove the position pin 15 from the fly jib bracket A 18 until the position pin 14 is fully inserted into the hole of the bracket 21 Incorrect fitting order may cause a serious hazard The position pin 14 must always be ins...

Page 381: ...turn it toward to the front of the Main boom 6 Fit the connection hole of the No 1 Fly jib 2 to the hole B of bracket 22 on the left side of the Main boom tip 7 Once the connection hole of the No 1 Fly jib 2 and the hole B of the bracket 22 on the left side of the Main boom tip are adjusted insert the position pin 15 to the hole then secure it with the linchpin 20 NOTES Move up and down or right a...

Page 382: ...er of the harness connection part 17 Main boom side and extract the harness plug 26 in the connector 25 NOTES Removed harness plug 26 will be later inserted into a connector in the harness connection part 16 Fly jib side After harness exchange the Main boom side 3 Insert the dummy plug 24 as extracted in 1 above to the connector 25 Don t forget to attach the dummy plug 24 into the connector 25 in ...

Page 383: ...e wind randomly around the winch drum 1 Lower the hook so that it almost touches the ground 2 Lower the boom to allow the hook to ground 3 Remove a bolt 29 and extract a wedge socket pin 28 then remove the wire socket 27 from the Main boom 4 Detach the wire clip 30 5 Using a bar A with a diameter of 6 to 8mm to apply to the rope wedge 31 and hammer it lightly so that the rope wedge 31 is removed 6...

Page 384: ... rope and result in a potentially serious hazard 12 Put the wire rope 8 through the wire socket 27 as detached in 9 above and set the rope wedge 31 to position a Pull the wire rope 8 intensely to the direction of the arrow 13 Attach the rope clip 30 to the wire rope 8 Refer to the Figure on the right for the rope clip position 14 Insert the wire socket 27 into connection base A inside the hook 11 ...

Page 385: ...re the extended No 2 Fly jib 3 2 Hold handles on the both sides of the tip of No 2 Fly jib 3 and draw it forward for extension 3 When the No 2 Fly jib 3 is extended adjust the both of side holes of the No 1 Fly jib 2 and No 2 Fly jib 3 to insert the position pin 12 Apply the linchpin 20 to secure the position pin 6 3 RETRACTING NO 2 FLY JIB To retract the No 2 Fly jib reverse the procedure as desc...

Page 386: ...ct over hoist detector the Fly jib side Before harness exchange 1 Open the cover of the harness connection part 16 Fly jib side and extract the harness plug 26 in the connector 23 NOTES The removed harness plug 26 will be later inserted into a connector in the harness connection part 17 Main boom side Before harness exchange the Main boom side 2 Open the cover of the harness connection part 17 Mai...

Page 387: ...or 23 Don t forget to attach the dummy plug 24 into the connector 23 in the harness connection part 16 Fly jib side If not the absence of the dummy plug may cause mis function of the over hoist detector In such event it may cause the hook or load to drop and result in a serious hazard 3 Pull the linchpin 20 out from the position pin 15 placed in the bracket hole 22 on the left side of the Main boo...

Page 388: ...use a serious hazard The position pin 15 must always be inserted downward from the upper side Otherwise where it is inserted upward from the underside the position pin could easily drop down to cause the Fly jib to collapse and may cause a serious hazard CAUTION When the position pins 14 and 15 are fitted in both holes of the bracket 21 on the right side of the Main boom tip and Fly jib bracket A ...

Page 389: ...he underside the position pin could easily drop down to cause the Fly jib to drop and may cause a serious hazard 9 Keeping the hook stowage switch pushed operate winch to eliminate wire rope 8 slack For hook stowage operations do not turn ON the Moment limiter emergency release switch In such a condition the hook stowage mode is not available and may result in damaging the hook stowing bracket boo...

Page 390: ...d to fall breakage of the boom or turnover of machine due to overloading leading to serious injury or even resulting in death CAUTION In this section the devices indicated are exclusive for The Fly jib model but different from that of a standard model For devices other than these refer to the section Operation 2 4 Moment Limiter Overload detector 7 1 MOMENT LIMITER DISPLAY 6 20 ...

Page 391: ...tch SETUP CANCEL 14 Lifting height upper limit switch 15 Check switch 16 Cancel switch 17 Overwind detection LED Red 18 1 fall LED Green 19 2 fall LED Green 20 4 fall LED Green 21 Fly jib length 1 LED Orange 22 Fly jib length 2 LED Orange 23 Over un winding detection LED Red 24 Boom angle upper limit LED Orange 25 Boom angle Lower limit LED Orange 26 Working radius upper limit LED Orange 27 Liftin...

Page 392: ...sion of only 1 Fly jib section in use hence a wrong load working radius or lifting height will be indicated CAUTION Fly jib operations are limited to the boom angle range 55 degrees or more Where a load is hoisted in a condition that the boom angle is less than 55 degrees in addition to that that Main boom is extended for 50cm or longer the Moment limiter will issue an over load warning with an in...

Page 393: ...jib 1 value Rated working radius display 6 is switched to Fly jib 1 value Lifting height display 8 is switched to Fly jib 1 value 2 No 2 Fly jib mode When the 2 is ON in the Fly jib mode selection button rated load actual working radius and lifting height are switched to the Fly jib 2 condition Fly jib 2 section LED Orange is ON Total rated load display 3 is switched to Fly jib 2 value Rated worki...

Page 394: ... less load hoisting is not available as the Moment limter alarms the OVER LOAD However where the boom extension is less than 50cm the Moment limiter will not issue an over load warning When the Main boom is extended for 50cm or longer it cannot be lowered to the angle of less than 55 degrees Where the boom angle is less than 55 degrees it cannot be extended for 50cm or longer from its entirely ret...

Page 395: ...ion for transporting the Fly jib model To lift the Fly jib model lower the boom to the minimum and always use four hooking wire ropes Avoid fully raising the boom while using only two hooking wire ropes as the hooking wire ropes may interfere with the Fly jib which causes not only damage to the Fly jib but also an unstable lifting and results in tipping over of the machine 6 25 ...

Page 396: ...machine regularly until it has been operated for 100 hours that is the time when the machine will have settled down and may be considered as run in Any unusual noise at greasing points requires immediate greasing regardless of the maintenance period Use a grease type in the following table depending on the greasing point No Greasing Point Grease Type 1 Hook block greasing 2 pt Lithium grease 1 Gre...

Page 397: ...CATION section for other cautions not listed in this section 11 1 SPECIFICATIONS System Item LC785M 8B LC785M 8BF Machine mass 10 250kg 10 420kg Overall length x width x height 5 020mm x 2 360mm x 2 795mm Distance between idler and sprocket 2 235mm Track gauge 1 870mm Track width 450mm Mass and dimensions Lowest height from ground 360mm 11 2 DIMENSIONS 6 27 ...

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Page 399: ...PERATION MANUAL Document No 557E OM1202 00 First edition February 23 2012 Issued by Maeda Seisakusyo Co Ltd 1095 Onbegawa Shinonoi Nagano Nagano 388 8522 Japan No part of this manual can be reproduced in any from without permission ...

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